U.S. patent application number 16/872607 was filed with the patent office on 2020-08-27 for tangle-resistant decorative lighting assembly.
The applicant listed for this patent is Willis Electric Co., Ltd.. Invention is credited to Johnny CHEN.
Application Number | 20200271287 16/872607 |
Document ID | / |
Family ID | 1000004816502 |
Filed Date | 2020-08-27 |
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United States Patent
Application |
20200271287 |
Kind Code |
A1 |
CHEN; Johnny |
August 27, 2020 |
TANGLE-RESISTANT DECORATIVE LIGHTING ASSEMBLY
Abstract
A tangle-resistant decorative lighting assembly, comprising: a
main portion including a plurality of wires and connectors,
including first and second connectors and first and second
lighted-extension portions extending transversely from the main
portion. The first lighted extension portion including: a first
connector configured to detachably connect to the first connector
of the main portion, a first plurality of wires connected to the
first connector, and a first plurality of lamp assemblies connected
to the first plurality of wires. The second lighted-extension
portion including: a second connector configured to detachably
connect to the second connector of the main portion, a second
plurality of wires connected to the second connector, and a second
plurality of lamp assemblies connected to the second plurality of
wires. The first connector of the main portion comprises a lock
portion configured to engage with a lock portion of the first
connector of the first lighted-extension portion.
Inventors: |
CHEN; Johnny; (Taipei,
TW) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Willis Electric Co., Ltd. |
Taipei |
|
TW |
|
|
Family ID: |
1000004816502 |
Appl. No.: |
16/872607 |
Filed: |
May 12, 2020 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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16178175 |
Nov 1, 2018 |
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16872607 |
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15813011 |
Nov 14, 2017 |
10119664 |
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16178175 |
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15335197 |
Oct 26, 2016 |
9845925 |
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15813011 |
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15588114 |
May 5, 2017 |
10222037 |
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16178175 |
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14886344 |
Oct 19, 2015 |
9671097 |
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15588114 |
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14627427 |
Feb 20, 2015 |
9243788 |
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14886344 |
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14485911 |
Sep 15, 2014 |
9140438 |
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14627427 |
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14328221 |
Jul 10, 2014 |
9157588 |
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14485911 |
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16368681 |
Mar 28, 2019 |
10711954 |
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14328221 |
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15333535 |
Oct 25, 2016 |
10267464 |
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16368681 |
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16751056 |
Jan 23, 2020 |
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15333535 |
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16241745 |
Jan 7, 2019 |
10578289 |
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16751056 |
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15588114 |
May 5, 2017 |
10222037 |
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16241745 |
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14886344 |
Oct 19, 2015 |
9671097 |
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15588114 |
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14627427 |
Feb 20, 2015 |
9243788 |
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14886344 |
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14485911 |
Sep 15, 2014 |
9140438 |
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14627427 |
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14328221 |
Jul 10, 2014 |
9157588 |
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14485911 |
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62246423 |
Oct 26, 2015 |
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61877854 |
Sep 13, 2013 |
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62246423 |
Oct 26, 2015 |
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61877854 |
Sep 13, 2013 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F21V 23/06 20130101;
F21W 2121/006 20130101; F21S 4/15 20160101; H01R 25/003 20130101;
F21W 2121/00 20130101; H01R 13/627 20130101; F21V 23/001 20130101;
F21S 4/10 20160101 |
International
Class: |
F21S 4/15 20060101
F21S004/15; F21V 23/00 20060101 F21V023/00; F21V 23/06 20060101
F21V023/06; H01R 25/00 20060101 H01R025/00; H01R 13/627 20060101
H01R013/627 |
Claims
1. A tangle-resistant decorative lighting assembly, comprising: a
main portion including a plurality of internally-reinforced
decorative-lighting wires and a plurality of lighting assemblies,
the plurality of lighting assemblies mechanically and electrically
connected to the plurality of internally-reinforced
decorative-lighting wires.
Description
RELATED APPLICATIONS
[0001] The present application is a continuation of U.S. patent
application Ser. No. 16/178,175, filed Nov. 1, 2018, which is a
continuation of U.S. patent application Ser. No. 15/813,011, filed
Nov. 14, 2017, now U.S. Pat. No. 10,119,664, which is a
continuation of U.S. patent application Ser. No. 15/335,197, filed
Oct. 26, 2016, now U.S. Pat. No. 9,845,925, which claims the
benefit of U.S. Provisional Application No. 62/246,423, filed Oct.
26, 2015, the contents of which are incorporated herein by
reference in their entireties.
[0002] U.S. patent application Ser. No. 16/178,175, filed Nov. 1,
2018, is also a continuation-in-part of U.S. patent application
Ser. No. 15/588,114, filed May 5, 2017, now U.S. Pat. No.
10,222,037, which is a continuation of Ser. No. 14/886,344, filed
Oct. 19, 2015, now U.S. Pat. No. 9,671,097, which is a continuation
of Ser. No. 14/627,427, filed Feb. 20, 2015, now U.S. Pat. No.
9,243,788, which is a continuation of U.S. application Ser. No.
14/485,911, filed Sep. 15, 2014, now U.S. Pat. No. 9,140,438, which
is a continuation-in-part of U.S. application Ser. No. 14/328,221,
filed Jul. 10, 2014, now U.S. Pat. No. 9,157,588, which claims the
benefit of 61/877,854, filed Sep. 13, 2013, the contents of which
are incorporated herein by reference in their entireties.
[0003] The present application is also a continuation-in-part of
U.S. Ser. No. 16/368,681, filed Mar. 28, 2019, which is a
continuation of U.S. patent application Ser. No. 15/333,535, filed
Oct. 25, 2016, now U.S. Pat. No. 10,267,464, which claims the
benefit of U.S. Provisional Application No. 62/246,423, filed Oct.
26, 2015, the contents of which are incorporated herein by
reference in their entireties.
[0004] The present application is also a continuation-in-part of
U.S. patent application Ser. No. 16/751,056, filed Jan. 23, 2020,
which is a continuation of U.S. patent application Ser. No.
16/241,745, filed Jan. 7, 2019, now U.S. Pat. No. 10,578,289, which
is a continuation of U.S. patent application Ser. No. 15/588,114,
filed May 5, 2017, now U.S. Pat. No. 10,222,037, which is a
continuation of U.S. patent application Ser. No. 14/886,344, filed
Oct. 19, 2015, now U.S. Pat. No. 9,671,097, which is a continuation
of U.S. patent application Ser. No. 14/627,427, filed Feb. 20,
2015, now U.S. Pat. No. 9,243,788, which is a continuation of U.S.
patent application Ser. No. 14/485,911, filed Sep. 15, 2014, now
U.S. Pat. No. 9,140,438, which is a continuation-in-part of U.S.
patent application Ser. No. 14/328,221, filed Jul. 10, 2014, now
U.S. Pat. Nos. 9,157,588, 9,140,438 and 9,157,588 both claiming the
benefit of U.S. Provisional Application No. 61/877,854, filed Sep.
13, 2013, the contents of which are all incorporated herein by
reference in their entireties.
FIELD OF THE DISCLOSURE
[0005] The present invention is generally directed to decorative
lighting. More specifically, the present invention is directed to
decorative lighting assemblies, including net lights and icicle
lights that are resistant to tangling and that provide consumer
safety and convenience features.
BACKGROUND OF THE INVENTION
[0006] Decorative lighting assemblies, and in particular net lights
and "icicle" lights are traditionally assembled using elaborate
patterns of interconnected wires and lights to form a particular
desired shape or structure. Net lights, for example, often form
rectangular or square outlines using zig-zag patterns of conductors
powering incandescent or light-emitting diode (LED) lamps. Icicle
lights, with their various draping lengths of series-connected
lamps rely on lengths of twisted wires across a top section and for
each "icicle" drop.
[0007] In both cases, the extensive lengths of wire conductors
twisted together to form the desired shape or outline of such
decorative assemblies results in a consumer product prone to
tangling. Not only does such tangling of wires result in consumer
frustration, but the untangling of the wires can result in wires
being pulled from their connectors, resulting in potential safety
hazards.
SUMMARY OF THE INVENTION
[0008] Embodiments of the present disclosure provide decorative
lighting assemblies, including net lights and icicle lights, that
are less prone to tangling than traditional decorative lighting
assemblies. As described below, the use of unique wire and lamp
connectors, the layout of the wires, and in some cases, the
reduction of wires between lamps, contributes to the
tangle-resistant or tangle-reduced features of the embodiments.
[0009] In addition to the tangle-resistant features, an embodiment
includes a decorative lighting assembly configured as an icicle
light string that includes a main portion with detachably connected
lighted-extension portions, or icicle drops. The connector system
connecting the main portion and the lighted-extension portions
includes features relating to safety and convenience, as described
further below.
[0010] One embodiment includes a tangle-resistant decorative
lighting assembly, comprising: a main portion including a plurality
of wires and connectors, including first and second connectors and
first and second lighted-extension portions extending transversely
from the main portion. The first lighted extension portion
including: a first connector configured to detachably connect to
the first connector of the main portion, a first plurality of wires
connected to the first connector, and a first plurality of lamp
assemblies connected to the first plurality of wires. The second
lighted-extension portion including: a second connector configured
to detachably connect to the second connector of the main portion,
a second plurality of wires connected to the second connector, and
a second plurality of lamp assemblies connected to the second
plurality of wires. The first connector of the main portion
comprises a lock portion configured to engage with a lock portion
of the first connector of the first lighted-extension portion.
[0011] Another embodiment includes decorative lighting connection
system, comprising: a first connector for connection to a main
portion of a decorative lighting assembly, the first connector
including: a first body portion comprising a generally
non-conductive portion and defining a first receiving channel; and
a first lock portion; a second connector configured to connect to
the first connector, the second connector including: a second body
portion comprising a generally non-conductive portion and having a
first portion configured to be inserted into the first channel of
the first body portion of the first connector, the first portion of
the second body defining a first channel; and a second lock portion
configured to engage with the first lock portion; a first wire
assembly including a first wire and a first electrically-conductive
terminal connected to the first wire, the first
electrically-conductive terminal and a portion of the first wire
assembly located within the first receiving cavity; a second wire
assembly including a second wire and a second
electrically-conductive terminal connected to the second wire, the
second electrically-conductive terminal and a portion of the second
wire assembly located within the first receiving cavity; wherein
the first connector is further configured such that insertion of
the first portion of the first connector into the receiving cavity
of the first connector causes the first electrically-conductive
terminal to contact the second electrically-conductive
terminal.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The invention can be understood in consideration of the
following detailed description of various embodiments of the
invention in connection with the accompanying drawings, in
which:
[0013] FIG. 1 is a plan view showing an illustrative embodiment of
a decorative lighting assembly;
[0014] FIG. 2 is a plan view showing an additional illustrative
embodiment of the decorative lighting assembly shown in FIG. 1;
[0015] FIG. 3 is a plan view showing an additional illustrative
embodiment of the decorative lighting assembly shown in FIG. 1;
[0016] FIG. 4 is a plan view showing an additional illustrative
embodiment of the decorative lighting assembly shown in FIG. 1;
[0017] FIG. 5A is an exploded perspective view showing a power
wire, an intermediate wire, and a bushing;
[0018] FIG. 5B is a perspective view showing the second power wire,
the intermediate wire, and the bushing shown in of FIG. 5A;
[0019] FIG. 5C is a perspective view showing the second power wire,
the intermediate wire, and the bushing shown in of FIG. 5A;
[0020] FIG. 6A is an exploded perspective view showing portions of
a cord and a male portion of a fastener C;
[0021] FIG. 6B is an additional perspective view showing the cord
and the male portion the fastener shown in FIG. 6A;
[0022] FIG. 6C is an exploded perspective view showing the male
portion of the fastener and the female portion of the fastener
shown in FIG. 6B;
[0023] FIG. 6D is an exploded perspective view showing the cord and
first power wire of FIG. 6C coupled by the fastener;
[0024] FIG. 7A is a perspective view showing a connector;
[0025] FIG. 7B is a perspective view showing a connector;
[0026] FIG. 8A is a perspective view showing an alternate
embodiment of the connector shown in FIG. 7A and FIG. 7B;
[0027] FIG. 8B is a plan view of the connector shown in FIG.
8A;
[0028] FIG. 9A is a perspective view showing an alternate
embodiment of the connector shown in FIG. 7A and FIG. 7B;
[0029] FIG. 9B is a plan view of the connector shown in FIG.
9A;
[0030] FIG. 10A is an exploded perspective view showing a male
portion of a connector and a female portion of the connector, a
first portion of a power wire, a second portion of the power wire
and an intermediate wire;
[0031] FIG. 10B is a partially assembled perspective view showing
the male portion of the connector and the female portion of the
connector shown in FIG. 10B;
[0032] FIG. 10C is an assembled perspective view showing the male
portion of the connector and the female portion of the connector
shown in FIG. 10B; and
[0033] FIG. 10D is a section view further illustrating the male
portion of the connector and the female portion of the connector
shown in FIG. 10B.
[0034] FIG. 11A is a prior art depiction of an icicle-light
decorative lighting assembly;
[0035] FIG. 11B is another prior art depiction of an icicle-light
decorative lighting assembly;
[0036] FIG. 12A is a perspective view of a decorative lighting
assembly according to an embodiment of the present disclosure;
[0037] FIG. 12B is a partially exploded view of the decorative
lighting assembly of FIG. 12A;
[0038] FIG. 13A is a perspective view of an embodiment of a female
2-wire connector and wires, according to an embodiment of the
present disclosure;
[0039] FIG. 13B is a perspective view of the 2-wire connectors and
wires of FIG. 13A assembled together;
[0040] FIG. 14A is a perspective view of an embodiment of a female
3-wire connector and wires, according to an embodiment of the
present disclosure;
[0041] FIG. 14B is a perspective view of the 3-wire connector and
wires of FIG. 13A assembled together;
[0042] FIG. 15A is a perspective view of a male 2-wire connector
and wire assembly for connection to the female connector of FIGS.
13A and 13B;
[0043] FIG. 15B is a partially exploded view of view of 2-wire
connector with wires of FIG. 15A;
[0044] FIG. 16 is a perspective view of the male and female
connectors of FIGS. 13B and 15A coupled together;
[0045] FIG. 17 is a perspective view of the male and female
connectors of FIGS. 14A and 15A coupled together;
[0046] FIG. 18A is a perspective view of a female 4-wire connector
assembled with wires, according to an embodiment of the present
disclosure;
[0047] FIG. 18B is a partially exploded view of the connector and
wires of FIG. 18A;
[0048] FIG. 19 is a perspective view of the male and female
connectors of FIGS. 18A and 15A coupled together;
[0049] FIG. 20 is a perspective view of another decorative lighting
assembly according to an embodiment of the present disclosure;
[0050] FIG. 21 is a partially exploded view of the decorative
lighting assembly of FIG. 12C;
[0051] FIG. 22A is a perspective view of an embodiment of a female
2-wire connector and wires, according to an embodiment of the
present disclosure;
[0052] FIG. 22B is a perspective view of the 2-wire connectors and
wires of FIG. 13A assembled together;
[0053] FIG. 23A is a perspective view of a 3-wire connector
assembled to wires, according to an embodiment of the present
disclosure;
[0054] FIG. 23B is a partially exploded view of the embodiment of
the female 3-wire connector and wires of FIG. 23A;
[0055] FIG. 24A is a perspective view of a female 4-wire connector
assembled with wires, according to an embodiment of the present
disclosure;
[0056] FIG. 24B is a partially exploded view of the connector and
wires of FIG. 24A;
[0057] FIG. 25A is a perspective view of a male 2-wire connector
and wire assembly for connection to the female connector of FIGS.
22A and 22B;
[0058] FIG. 25B is a partially exploded view of view of the male
2-wire connector with wires of FIG. 15A;
[0059] FIG. 26 is a perspective view of the male and female
connectors of FIGS. 22A and 25A coupled together;
[0060] FIG. 27 is a perspective view of the male and female
connectors of FIGS. 23A and 25A coupled together;
[0061] FIG. 28 depicts the male and female connectors of FIGS. 24A
and 25A coupled together;
[0062] FIG. 29A is a perspective view of an embodiment of a female
2-wire connector and wires, according to an embodiment of the
present disclosure;
[0063] FIG. 29B is a perspective view of the 2-wire connectors and
wires of FIG. 29A assembled together;
[0064] FIG. 29C is a cross-sectional view of the connector and
wires of FIG. 29B;
[0065] FIG. 30A is a perspective view of a 3-wire connector
assembled to wires, according to an embodiment of the present
disclosure;
[0066] FIG. 30B is a partially exploded view of the embodiment of
the female 3-wire connector and wires of FIG. 30A;
[0067] FIG. 31A is a perspective view of a female 4-wire connector
assembled with wires, according to an embodiment of the present
disclosure;
[0068] FIG. 31B is a partially exploded view of the connector and
wires of FIG. 24A;
[0069] FIG. 32A is a perspective view of a male 2-wire connector
and wire assembly for connection to the female connector of FIGS.
29A and 29B;
[0070] FIG. 32B is a partially exploded view of view of the male
2-wire connector with wires of FIG. 15A;
[0071] FIG. 32C is a sectional view of the male 2-wire connector of
FIG. 32A with wires inserted;
[0072] FIG. 33A is a perspective view of the male and female
connectors of FIGS. 29A and 32A coupled together;
[0073] FIG. 33B is a section view of the coupled connectors of FIG.
33A, with wires not depicted in sectional view;
[0074] FIG. 34 is a perspective view of the male and female
connectors of FIGS. 31A and 32A coupled together; and
[0075] FIG. 35 is a perspective view of the male and female
connectors of FIGS. 31A and 32A coupled together.
[0076] FIG. 36 is a perspective view of a reinforced decorative
wire, according to an embodiment of the claimed invention.
[0077] FIG. 37A is a cross-sectional view of the reinforced
decorative wire of FIG. 36.
[0078] FIG. 37B is a cross-sectional view of the reinforced
decorative wire of FIG. 36, depicting variations in conductor and
strand position caused during manufacturing.
[0079] FIG. 38 is a cross-sectional view of another embodiment of a
reinforced decorative wire, according to an embodiment of the
claimed invention.
[0080] FIG. 39 is a cross-sectional view of another embodiment of a
reinforced decorative wire, according to an embodiment of the
invention.
[0081] While the invention is amenable to various modifications and
alternative forms, specifics thereof have been shown by way of
example in the drawings and will be described in detail. It should
be understood, however, that the intention is not to limit the
invention to the particular embodiments described. On the contrary,
the intention is to cover all modifications, equivalents, and
alternatives falling within the spirit and scope of the invention
as defined by the appended claims.
DETAILED DESCRIPTION
[0082] FIG. 1 is a plan view showing an illustrative embodiment of
a decorative lighting assembly 100. Decorative lighting assembly
100 comprises a first power wire 102 and a second power wire 104.
In FIG. 1, first power wire 102 and second power wire 104 are
cooperating to surround a display area 106 of decorative lighting
assembly 100. With reference to FIG. 1 it will be appreciated that
decorative lighting assembly 100 includes a plurality of lamp
assemblies 108 distributed across display area 106. The plurality
of lamp assemblies 108 include a first column 120A of lamp
assemblies 108 aligned along a first line 122A, a second column
120B of lamp assemblies 108 aligned along a second line 122B, and a
third column 120C of lamp assemblies 108 aligned along a third line
122C.
[0083] A plurality of lamp assemblies 108 of decorative lighting
assembly 100 may be inter-connected by wires to form one or more
electrical circuits. A plurality of lamp assemblies 108 of
decorative lighting assembly 100 may be mechanically coupled by
cords which provide mechanical support. In some embodiments, the
wires and the cords cooperate to form a net-like structure. In the
embodiment of FIG. 1, the plurality of lamp assemblies 108 include
a fourth column 120D of lamp assemblies 108 aligned along a first
line 122D and a fifth column 120E of lamp assemblies aligned along
a fifth line 122E.
[0084] Decorative lighting assembly 100 of FIG. 1 includes a power
plug 124. Power plug 124 may comprise a traditional power plug
comprising housing 126, first power terminal 128A and a second
power terminal 128B for plugging into an outlet of an external
power source, which may be an alternating-current (AC) power
source. First power wire 102 is electrically connected to first
power terminal 128A of power plug 124. Second power wire 104 is
electrically connected to second power terminal 128B of power plug
124. In some embodiments, first power wire 102 and second power
wire 104 may comprise a reinforced wire such as the reinforced wire
described in published U.S. Patent Application US20150167944 (Now
U.S. Pat. No. 9,243,788), filed Feb. 10, 2015, and entitled
Decorative Lighting with Reinforced Wiring, which is herein
incorporated by reference in its entirety.
[0085] With reference to FIG. 1, it will be appreciated that
display area 106 of decorative lighting assembly 100 has a shape
generally corresponding to a four-sided polygon. In the embodiment
of FIG. 1, the shape of display area generally corresponds to a
rectangle having a first long side, a second long side, a first
short side, and a second short side. First power wire 102 defines
the first short side, the first long side, and the second short
side of a rectangle in the embodiment of FIG. 1. Second power wire
104 defines the second long side of a rectangle in the embodiment
of FIG. 1.
[0086] FIG. 2 is a plan view showing an additional illustrative
embodiment of decorative lighting assembly 100 shown in the
previous figure. Decorative lighting assembly 100 comprises a first
power wire 102 and a second power wire 104. In FIG. 2, first power
wire 102 and second power wire 104 are cooperating to surround a
display area 106 of decorative lighting assembly 100. With
reference to FIG. 2 it will be appreciated that decorative lighting
assembly 100 includes a plurality of lamp assemblies 108
distributed across display area 106. The plurality of lamp
assemblies 108 include a first column 120A of lamp assemblies 108,
a second column 120B of lamp assemblies 108, a third column 120C of
lamp assemblies 108, and a fourth column 120D of lamp assemblies
108.
[0087] In the embodiment of FIG. 2, a plurality of intermediate
wires 130 are disposed along a first zig-zag path 132A connecting
the lamp assemblies in first column 120A with the lamp assemblies
in second column 120B. In some embodiments, decorative lighting
assembly 100 may include a cord that is disposed along a second
zig-zag path connecting the lamp assemblies in second column 120B
with the lamp assemblies in third column 120C. In the embodiment of
FIG. 2, decorative lighting assembly 100 includes a plurality of
intermediate wires 130 that are disposed along a third zig-zag path
132C connecting the lamp assemblies in third column 120C with the
lamp assemblies in fourth column 120D. In some embodiments,
intermediate wires 130, first power wire 102 and second power wire
104 may comprise a reinforced wire such as the reinforced wire
described in published U.S. Patent Application US20150167944 (Now
U.S. Pat. No. 9,243,788), which is herein incorporated by reference
in its entirety.
[0088] Decorative lighting assembly 100 of FIG. 2, includes a first
series circuit 134A comprising a first lamp assembly 108A
electrically connected to first power wire 102 at a connector B1
and an nth lamp assembly 108N electrically connected to second
power wire 104 at a connector B2. In the embodiment of FIG. 2, a
plurality of intermediate lamp assemblies 108 are electrically
connected in series between first lamp assembly 108A and nth lamp
assembly 108A.
[0089] With reference to FIG. 2, it will be appreciated that first
series circuit 134 follows a winding path between connector B1 and
connector B2 so that the lamp assemblies 108 are distributed across
display area 106. In the embodiment of FIG. 2, the winding path of
first series circuit 134 includes a plurality of intermediate wires
130 disposed along the first zig-zag path 132A connecting the lamp
assemblies in first column 120A with the lamp assemblies 108 in
second column 120B. First series circuit 134 also includes the
plurality of intermediate wires 130 disposed along third zig-zag
path 132C connecting the lamp assemblies 108 in third column 120C
with the lamp assemblies 108 in fourth column 120D.
[0090] FIG. 3 is a plan view showing an additional illustrative
embodiment of decorative lighting assembly 100 shown in the
previous figure. Decorative lighting assembly 100 comprises a first
power wire 102 and a second power wire 104. In FIG. 3, first power
wire 102 and second power wire 104 are cooperating to surround a
display area 106 of decorative lighting assembly 100. With
reference to FIG. 3 it will be appreciated that decorative lighting
assembly 100 includes a plurality of lamp assemblies 108
distributed across display area 106. The plurality of lamp
assemblies 108 include a first column 120A of lamp assemblies 108,
a second column 120B of lamp assemblies 108, a third column 120C of
lamp assemblies 108, a fourth column 120 of lamp assemblies 108,
and a fifth column 120E of lamp assemblies 108.
[0091] In the embodiment of FIG. 3, a plurality of lamp assemblies
108 of decorative lighting assembly 100 are mechanically coupled by
cords 136 which provide mechanical support. In some embodiments, a
plurality of lamp assemblies 108 of decorative lighting assembly
100 may be inter-connected by wires to form one or more electrical
circuits. In some embodiments, the wires and the cords cooperate to
form a net-like structure.
[0092] Decorative lighting assembly 100 of FIG. 1, includes a cord
136 that is disposed along a second zig-zag path 132A connecting
the lamp assemblies in second column 120B with the lamp assemblies
in third column 120C. In the embodiment of FIG. 3, cord 136 also
extends along a fourth zig-zag path 132D connecting the lamp
assemblies in fourth column 120D with the lamp assemblies in fifth
column 120E. Cord 136 is illustrated using dashed lines in FIG. 3.
In some embodiments, cord 136 may comprise a plurality of cord
segments.
[0093] In the embodiment of FIG. 3, cord 136A comprises a single
cord that extends through both second zig-zag path 132B and the
fourth zig-zag path 132D. Decorative lighting assembly 100 of FIG.
3, includes a fastener C that mechanically couples a first end of
cord 136A and a second end of cord 136A to first power wire 102. In
the embodiment of FIG. 3, first power wire 102 extends through a
passageway defined by fastener C.
[0094] Decorative lighting assembly 100 of FIG. 3 also includes a
bushing A2 that mechanically couples an intermediate portion of
cord 136A to second power wire 104. In the embodiment of FIG. 3,
cord 136A and second power wire 104 extend through a passageway
defined by bushing A2. Also in the embodiment of FIG. 3, cord 136A
extends through a passageway defined by a clip of each lamp
assembly 108 in second column 120A and each lamp assembly 108 in
third column 120C.
[0095] FIG. 4 is a plan view showing an additional illustrative
embodiment of decorative lighting assembly 100 shown in the
previous figure. Decorative lighting assembly 100 comprises a first
power wire 102 and a second power wire 104. In FIG. 4, first power
wire 102 and second power wire 104 are cooperating to surround a
display area 106 of decorative lighting assembly 100. With
reference to FIG. 4 it will be appreciated that decorative lighting
assembly 100 includes a plurality of lamp assemblies 108
distributed across display area 106. The plurality of lamp
assemblies 108 include a first column 120A of lamp assemblies 108,
a second column 120B of lamp assemblies 108, a third column 120C of
lamp assemblies 108, a fourth column 120 of lamp assemblies 108,
and a fifth column 120E of lamp assemblies 108.
[0096] In the embodiment of FIG. 4, a plurality of lamp assemblies
108 of decorative lighting assembly 100 are inter-connected by
intermediate wires 130 to form electrical circuits. Also in the
embodiment of FIG. 4, a plurality of lamp assemblies 108 of
decorative lighting assembly 100 are mechanically coupled by cords
136 which provide mechanical support. In the embodiment of FIG. 4,
the wires and the cords cooperate to form a net-like structure. For
purposes of illustration, the cords are illustrated using dashed
lines and the wires are illustrated using solid lines in FIG.
4.
[0097] In the embodiment of FIG. 4, a plurality of intermediate
wires 130 are disposed along a first zig-zag path 132A connecting
the lamp assemblies in first column 120A with the lamp assemblies
in second column 120B. Also in the embodiment of FIG. 4, decorative
lighting assembly 100 includes a cord 136A that extends along a
second zig-zag path 132B connecting the lamp assemblies in second
column 120B with the lamp assemblies in third column 120C. A
plurality of intermediate wires 130 are disposed along a third
zig-zag path 132C connecting the lamp assemblies in third column
120C with the lamp assemblies in fourth column 120D. In the
embodiment of FIG. 4, cord 136A extends along a fourth zig-zag path
132D connecting the lamp assemblies in fourth column 120D with the
lamp assemblies in fifth column 120E. Cord 136A is illustrated
using dashed lines in FIG. 4. In some embodiments, cord 136A may
comprise a plurality of cord segments.
[0098] In the embodiment of FIG. 4, cord 136A comprises a single
cord that extends through both second zig-zag path 132B and the
fourth zig-zag path 132D. Decorative lighting assembly 100 of FIG.
4, includes a fastener C that mechanically couples a first end of
cord 136A and a second end of cord 136A to first power wire 102. In
the embodiment of FIG. 4, first power wire 102 extends through a
passageway defined by fastener C.
[0099] With reference to FIG. 4, it will be appreciated that a
top-most intermediate wire extends between a top-most lamp assembly
in first column 120A and a top-most lamp assembly in third column
120C. In the embodiment of FIG. 4, a bushing A1 mechanically
couples an intermediate portion of the first top-most intermediate
wire to second power wire 104. In the embodiment of FIG. 4, the
second power wire 104 and the top-most intermediate wire extend
through a passageway defined by bushing A1.
[0100] In some embodiments of decorative lighting assembly 100, the
intermediate wires 130 have a first outer diameter, the cords 136
have a second outer diameter, and the second outer diameter is
substantially equal to the first outer diameter so that decorative
lighting assembly 100 has a uniform appearance.
[0101] In some embodiments of decorative lighting assembly 100, the
intermediate wires 130 comprise a plurality of conductor strands
and an outer insulating layer adjacent to, and covering, one or
more of the conductor strands. The cords 136 may comprise a solid
strand. In some embodiments of decorative lighting assembly 100,
the insulating layer of the intermediate wires 130 and the solid
strand of the cords 136 comprise the same material so that the
decorative lighting assembly has a uniform appearance. In some
embodiments of decorative lighting assembly 100, the insulating
layer of the intermediate wires 130 and the solid strand of the
cords 136 are substantially the same color so that the decorative
lighting assembly has a uniform appearance.
[0102] In some embodiments of decorative lighting assembly 100, the
first power wire comprises 18 AWG wire, the second power wire
comprises 18 AWG wire, and the intermediate wires comprise 22 AWG
wire.
[0103] In some embodiments of decorative lighting assembly 100, the
first power wire comprises 18 AWG wire, the second power wire
comprises 18 AWG wire, and the intermediate wires comprise 22 AWG
reinforced wire.
[0104] In some embodiments of decorative lighting assembly 100, the
first power wire comprises 18 AWG wire, the second power wire
comprises 18 AWG wire, and the intermediate wires comprise 25 AWG
reinforced wire.
[0105] FIG. 5A is an exploded perspective view showing a second
power wire 104, an intermediate wire 130, and a bushing A1. FIG. 5B
is a perspective view showing second power wire 104, intermediate
wire 130, and bushing A1 of FIG. 5A in an assembled state. In FIG.
5B, intermediate wire 130 and second power wire 104 can be see
extending through a passageway P defined by bushing A1.
[0106] FIG. 5C is a perspective view showing a second power wire
104, a cord 136, and a bushing A2. In the embodiment of FIG. 5C,
cord 136A and second power wire 104 extend through a passageway P
defined by bushing A2.
[0107] FIG. 6A is an exploded perspective view showing portions of
a cord 136A and a male portion 142M of fastener C. A first end 140A
and a second end 140B of cord 136A are visible in FIG. 6A.
[0108] FIG. 6B is an additional perspective view showing portions
of cord 136A and male portion 142M of fastener C. In the embodiment
of FIG. 6B, first end 140A and second end 140B of cord 136A are
fixed to male portion 142M of fastener C.
[0109] FIG. 6C is an exploded perspective view showing a male
portion 142M of fastener C and a female portion 142F of fastener C.
In the embodiment of FIG. 6C, first end 140A and second end 140B of
cord 136A are fixed to male portion 142M of fastener C. In FIG. 6C,
a first power wire 102 can be seen extending through a passageway P
defined by female portion 142F of fastener C.
[0110] FIG. 6D is an exploded perspective view showing cord 136
coupled to first power wire 102A by fastener C. In the embodiment
of FIG. 6D, first end 140A and second end 140B of cord 136A are
fixed to male portion 142M of fastener C. In FIG. 6D, first power
wire 102 can be seen extending through a passageway P defined by
fastener C.
[0111] FIG. 7A is a perspective view showing a connector B2. In the
embodiment of FIG. 7A, a first portion 144A of a power wire 102, a
second portion 144B of power wire 102 and an intermediate wire 130
are electrically connected to each other by connector B2. The
embodiment of FIG. 7A also includes a cord 136. In the embodiment
of FIG. 7A, cord 136, first portion 144A of power wire 102, second
portion 144B of power wire 102, and intermediate wire 130 are all
mechanically coupled to each other by connector B2.
[0112] FIG. 7B is a perspective view showing a connector B2. In the
embodiment of FIG. 7B, connector B2 is sectioned so that one end of
cord 136 can be seen captured inside connector B2. In the
embodiment of FIG. 7B, cord 136, first portion 144A of power wire
102, second portion 144B of power wire 102, and intermediate wire
130 are all mechanically coupled to each other by connector B2.
First portion 144A of a power wire 102, a second portion 144B of
power wire 102 and an intermediate wire 130 are electrically
connected to each other by connector B2 in the embodiment of FIG.
7B.
[0113] FIG. 8A is a perspective view showing an alternate
embodiment of connector B2 shown in FIG. 7A and FIG. 7B.
[0114] FIG. 8B is a plan view showing the connector B2 shown in
FIG. 8A.
[0115] FIG. 9A is a perspective view showing an alternate
embodiment of connector B2 shown in FIG. 7A and FIG. 7B.
[0116] FIG. 9B is a plan view showing the connector B2 shown in
FIG. 9A.
[0117] FIG. 10A is an exploded perspective view showing a male
portion 154M of connector B1 and a female portion 152F of connector
B1. A first portion 154A of a power wire 102, a second portion 154B
of power wire 102 and an intermediate wire 130 are all illustrated
in the exploded view of FIG. 10A.
[0118] FIG. 10B is a partially assembled perspective view showing
male portion 154M of connector B1 and female portion 152F of
connector B1. In the embodiment of FIG. 10B, first portion 154A of
power wire 102 has been inserted into male portion 154M of
connector B1. Also in the embodiment of FIG. 10B, a second portion
154B of power wire 102 and an intermediate wire 130 have been
inserted into female portion 154F of connector B1.
[0119] FIG. 10C is an assembled perspective view showing a male
portion 154M of connector B1 and a female portion 152F of connector
B1. In the embodiment of FIG. 10C, male portion 154M of connector
B1 has been inserted into female portion 152F of connector B1.
First portion 154A of power wire 102, second portion 154B of power
wire 102 and intermediate wire 130 all are electrically connected
to each other by connector B2 in the embodiment of FIG. 10C. First
portion 154A of power wire 102, second portion 154B of power wire
102, and intermediate wire 130 are also mechanically coupled to
each other by connector B2 in the embodiment of FIG. 10C.
[0120] FIG. 10D is a section view further illustrating male portion
154M of connector B1 and female portion 152F of connector B1.
[0121] Referring first to FIGS. 11A and 11B, prior-art icicle light
assemblies depicted. Referring to FIG. 11A, in this traditional
decorative lighting assembly, segments of wires, i.e., insulated
electrical conductors, interconnect multiple lamp holders 10 with
lamps 13. The structure includes a top, horizontally extending
portion 15 comprising twisted portions of wires, as well as
multiple vertically extending portions of "icicle" drops 17 with
lamps wired, typically, in an electrical series connection.
[0122] Referring also to FIG. 11B, a schematic of a typical
prior-art icicle light assembly before twisting is depicted. As
depicted, long strands of wires interconnect lamps 12 and 22.
[0123] Typically, such known decorative lighting structures form
one integral, contiguous lighting assembly not intended to be
separated, save for lamps.
[0124] Referring to FIGS. 12A-35, embodiments of tangle-resistant
decorative lighting assemblies and connectors for "icicle" lights
of the disclosure are depicted.
[0125] As described further below, embodiments of the present
disclosure may employ some traditional wire-twisting features found
in the prior art, but are distinguished in part by the wiring and
connection structures that allow individual icicle drops to be
connected and disconnected from the main horizontal wiring. As will
also be described further below, the connectors and wiring
structures not only provide features convenient to consumers using
the lighting assemblies, but also provide benefits relating to ease
of manufacturing.
[0126] Referring to FIGS. 12A and 12B, an embodiment of decorative
lighting assembly 400 in the form of an icicle light assembly is
depicted. FIG. 12A depicts a fully-assembled version of decorative
lighting assembly 400, while in FIG. 12B, a partially-disassembled
version of decorative lighting assembly 400 is depicted.
[0127] In an embodiment, and as depicted, decorative lighting
assembly 400 includes main portion 402 and a plurality of lighted
extension portions 404, including lighted-extension portions 404a,
404b, 404c and 404d. In an embodiment, main portion 402 extends
horizontally, or latitudinally, while lighted-extension portions
404 extend vertically or longitudinally from main portion 402. In
an embodiment, lighted-extension portions 404 extend
perpendicularly or transversely to main portion 502, when assembled
and in a display position. In an embodiment, and as depicted,
lighted-extension portions 402 are not coupled to one another.
[0128] Because lighted-extension portions 404 are detachably
coupled to main portion 402, they may be detached and replaced in
the event of a failure of lamp assemblies, connectors, and so on.
Further, the detachable nature of lighted-extension portions 404
allows different configurations of lighted-extension portions to be
exchanged. As depicted in the figures, each portion 404 is intended
to be an "icicle strand" or "icicle drop", giving the appearance of
winter icicles, perhaps displayed at a rooftop edge. In other
embodiments, the icicle-drop style portion 404 may be replaced with
another electrically-compatible portion 404, such as lighted
ornament (typically some sort of housing with a plurality of lamp
assemblies). In another embodiment, portions 404 having lamps of a
particular color may be exchanged for lamps of another color,
allowing for mixing and matching by a user to create a desired
color scheme.
[0129] Consequently, in an embodiment, decorative lighting assembly
400 may comprise a set comprising main portion 402 and
lighted-extension portions 404, wherein more extension portions 404
than can be accommodated by main portion 402, e.g., main portion
402 has connectors for 8 lighted-extension portions 404, but 16 are
provided. The extra portions 404 may be interchangeable, and
comprise different colors, comprise ornaments, or comprise other
lighting and decorative features.
[0130] In an embodiment, main portion 402 includes power plug 406,
optional end-power connector 408, main wiring 410, and a plurality
of connectors 412a.
[0131] In an embodiment, power plug 406 is configured to be
inserted into an external supply of power, such as a wall socket.
In other embodiments, power plug 406 may be configured to connect
to alternative source of power or control device.
[0132] Optional end-power connector 408, in an embodiment, is
configured to provide power to another decorative light assembly,
such as another decorative light assembly 400.
[0133] Main wiring 410, in an embodiment, comprises a plurality of
wires or wire segments. In an embodiment, and as depicted, main
wiring 410 includes wires 410a, 410b, 410c, 410d and a plurality of
wires 410e. In this embodiment, wires 410a and 410b are
mechanically and electrically connected, while wires 410c and 410d
are electrically connected. As also depicted, an end of wire 410 is
mechanically and electrically connected to a first electrical
terminal of power plug 406, and end of wire 410b is connected to a
first electrical terminal of optional end-power connector 408.
[0134] Wires 410c and 410d are mechanically and electrically
connected to one another, with an end of wire 410c connected to a
second terminal of power plug 406, while an end of wire 410d is
connected to a second terminal of end-power connector 408.
[0135] Wires 410e electrically connect connectors 412a. In an
embodiment, wires 410e connect to connectors 412a such that
connectors 412a (and 412b) and lamp assemblies of
lighting-extension portions 404 are electrically connected in
series.
[0136] In an embodiment, connectors 412a may be configured to
receive two or more wires. In an embodiment, connectors 412a may be
configured to receive two, three or four wires. More specifically,
connectors 412a3 are configured to receive three wires, such as
410c, 410d and 410e. Connectors 412a2 are configured to receive two
wires, such as a pair of wires 410e. Embodiments of connectors 412,
including connectors 412a2 and 412a3 are described further
below.
[0137] In some embodiments, some or all of wires 410 may comprise a
reinforced wire such as the reinforced wire described in published
U.S. Patent Application US20150167944, filed Feb. 10, 2015, and
entitled Decorative Lighting with Reinforced Wiring, which is
herein incorporated by reference in its entirety.
[0138] In this electrical configuration, when power is applied to
power plug 406, power is also available at end-power connector 408.
Wires 410a and 410b may be considered first polarity wires, such as
positive, live or hot, and wires 410c and 410d may be considered
second polarity wires, such as negative, or neutral.
[0139] As will be described further below, ends of wires may be
joined together with electrically-conductive terminals 413. In an
embodiment, terminals 413 not only couple wires together, but also
serve to connect wires to connectors 412a and connectors 412b of
lighting extension portions 410, as also described further
below.
[0140] In an embodiment, each lighted-extension portion 404,
including lighted-extension portions 404a, 404b, 404c and 404d,
includes connector 412b, a plurality of multiple lamp wires 414,
lamp holders 416 and lamp assemblies 418. Each lighted-extension
404 defines a connector end 401 and a free end 403. In an
embodiment, connector end 401 is connected to main portion 402,
while free end 403 is not connected to main portion 402 or other
lighted-extension portions 404. In one such embodiment, except for
the connection of end 401 to main portion 402, lighted-extension
portions 404 do not connect to any other adjacent structures. In an
embodiment, connector pair 412a/412b is not the same as lamp holder
416. In an embodiment, connectors 412a and 412b form a decorative
lighting connector system, and more specifically, a decorative
lighting lighted-extension connection system.
[0141] As described further below, each connector 412b of
lighting-extension portion is configured to mechanically and
electrically connect to a connector 412a of main portion 402. In
some embodiments, and as depicted, connector pairs 412a and 412b
are intended to be detachably coupled. In other embodiments,
connector pairs 412a and 412b are not detachably coupled, and are
not intended to be easily detached from one another by a consumer
after manufacturing assembly.
[0142] Lamp wires 414 electrically connect connector 412b to lamps
418, and connect lamps 418 to other lamps 418, in each
lighting-extension portion 404. In an embodiment, lamp wires 414
may be twisted about one another as depicted.
[0143] In an embodiment, a wire 414, such as 414a is connected to a
first terminal of a connector 412b, while another wire 414, such as
414b, is connected to a second terminal of the connector 412b. In a
series connected lighting assembly, such as is depicted, wire 414a
is electrically connected to a first lamp 418 (nearest the
connector 412b) in the lighting-extension portion 404, while wire
414b is electrically connected to a last lamp 418 in the
lighting-extension portion 404.
[0144] In the depicted embodiment, lighted-extension portion 404a
includes seven lamp assemblies 418, lighted-extension portion 404b
includes four lamp assemblies 418, lighted-extension portion 404c
includes six lamp assemblies 418, and lighted-extension portion
404d includes five lamp assemblies 418. The number of lamp
assemblies per lighted-extension portion 404 may vary depending on
the light pattern desired, and be different from that depicted.
[0145] In the embodiment depicted, decorative lighting assembly 400
includes 50 lamp assemblies 418 in total, with each lamp assembly
wired to the other in electrical series. In one such embodiment,
each lamp assembly is rated for approximately 2.5 volts, with an
expectation that decorative lighting assembly 400 will be powered
by an external alternating current (AC) power source providing
approximately 125 VAC.
[0146] In other embodiments, lamp assemblies 418 may be wired in
parallel, as described below, or may be wired in parallel
series.
[0147] Lamp assemblies 418 may comprise incandescent lamps or LEDs,
configured to operate on AC or DC power, and having various voltage
ratings, as will be understood by those of ordinary skill.
[0148] Referring to FIGS. 13A to 16B, embodiments of connectors
412a and 412b are depicted.
[0149] Referring specifically to FIGS. 13A and 13B, connector 412a2
is depicted. In the embodiment depicted, connector 412a2 includes
generally non-conductive body portion 430, first end 432, and
second end 434. In an embodiment, body portion 430 includes a pair
of user-gripping portions 436 and a pair of tabs 438. User-gripping
portions 436, in an embodiment, are configured to be gripped or
grasped by a user to assist in separating connector 412a and
connector 412b, and may comprise a pair of projections joined to
body portion 430 at first end 432. User-gripping portions 436 may
be configured to bend or pivot at their respective connection
points to end 432. Optional tabs 438, when present may prevent a
user's hand from slipping off of connector 412a, when gripping
portions 436 and pulling.
[0150] First end 432 of connector 412a (412a2 in this embodiment),
defines one or more openings or channels configured to receive
terminals 413, including terminals 413a, and wires, such as
410e.
[0151] Second end 434 of connector 412a defines a first receiving
channel 440 and a second receiving channel 442. Channels 440 and
442 may extend through body portion 430 to form the channels in
first end 432. In an embodiment, channels 440 and 442 are two
separate and distinct channels separated by an inner structure,
such as a wall 443. In another embodiment, not depicted, channels
440 and 442 combine to form a single channel to receive end 462 of
connector 412b, as described further below.
[0152] In an embodiment, channels 440 and 442 define dissimilar
shapes such that connector 412b may only be coupled to connector
412a in a single orientation. In an embodiment, and as depicted,
channel 440 defines a circular opening and a cylindrical channel,
while channel 442 defines a square opening. In an embodiment,
channels 440 and 442 extend the entire length of body portion
430.
[0153] As described further below, channels 440 and 442 are each
configured to receive a portion of connector 412b.
[0154] In an embodiment, body portion 430 includes lock portion 444
on surface 446. Lock portion 444 is configured to detachably
receive a lock portion of connector 412b, as will be described
further below. In the embodiment depicted and described, the lock
portion of the connectors may be locked and unlocked by a user
without the necessity of tools, i.e., can be locked and unlocked by
hand. This contrasts with a locking feature described further below
in an alternate embodiment where locking and unlocking requires
that an end user utilize a tool.
[0155] Still referring to FIGS. 13A and 13B, a pair of terminals
413a are attached to a pair of wires 410e, respectively.
[0156] In an embodiment, each terminal 413a includes a pair of
barbs or projections 450 attached at one end to a body portion 451
and configured to pivot about at the attached end. Projections 450
may take other shapes as needed to cooperate with connector 412 for
attachment.
[0157] Body portion 451, in an embodiment, defines an opening or
channel 452 configured to receive an end, or male portion, 415 of
terminal 413b of connector 412b. Body portion 451, in an
embodiment, defines a lengthwise slot 454, such that terminal 413a
comprises a spring, and is able to be radially expanded or
contracted when terminal 413b is inserted, or removed from,
terminal 413a.
[0158] Each terminal 413a is configured to be crimped onto, or
otherwise connected to, a conductive portion of a wire, such as a
wire 410e, such that terminal 413a is in mechanical and electrical
connection with the wire 410.
[0159] As depicted, terminal 413a, and a portion of wire 410e is
inserted into connector body 430 at end 432, and into channels 440
and 442. In an embodiment, when inserted into connector 412a,
projections, or barbs, 450, engage an inside surface or structure
of connector 412a, preventing terminal 413a from easily being
pulled back out of connector 412a after initial insertion.
[0160] Referring to FIGS. 15A and 15B, an embodiment of connector
412b is depicted. In an embodiment, connector 412b is a male
connector configured to couple with a female connector, such as
connector 412a, including connector 412a2, and in some embodiments
with any of connectors 412a2 (2-wire), 412a3 (3-wire), or 412a4
(4-wire). In an embodiment, connector 412b is simply a 2-wire
connector, though in other embodiments not depicted, connector 412b
is configured to receive 3-6 wires, including 3 wires or 4 wires.
Although connector 412a is described as being a "female" connector,
and connector 412b is described as being a "male" connector, it
will be understood that in other embodiments, connector structure
may be exchanged between connectors or connector portions such that
connector 412a may comprise a male connector and connector 412b may
comprise a female connector.
[0161] In an embodiment, connector 412b includes body portion 460,
first end 462, which is an insertion end, and second end 464 which
is a wire-receiving end. Second end 464 may also include one or
more tabs 465, which may be contacted by a user to assist with
pushing or pulling connector 412b. Connector 412b also includes
lock portion 466, and defines channels 468 and 470, divided by wall
471. In an embodiment, channels 468 and 470 extend the entire
length of body portion 460.
[0162] First end 462, in an embodiment, is configured to be
inserted into connector 412a. In an embodiment, first end 462
includes structure defining a shape complementary to the shapes
defined by channels 440 and 442, and thereby first end 462 is
insertable into end 434 of connector 412a. As depicted, a portion
of end 462 defines a complementary circular, cylindrical shape and
another portion defines a square shape, to fit into channels 440
and 442, respectively. In an embodiment, first end 462 comprises
first side or portion 463 corresponding to the circular,
cylindrical shape and configured to fit into channel 440, and
second side or portion 465 corresponding to the square-ended shape
and configured to fit into channel 442. In one such embodiment,
portions 463 and 465 are separated by a space intended to receive
wall 443 so as to enable end 462 to fit into end 434.
[0163] When connector 412b is inserted into connector 412a, in an
embodiment, channel 468 aligns with channel 440 to form a first
continuous channel in the coupled pair of connectors, and channel
470 aligns with channel 442 to form a second continuous channel in
the coupled pair of connectors 412a and 412b. In an embodiment,
"continuous" means that portions of channel 468 and channel 440, or
portions of 470 and 441, overlap, or share a common space.
[0164] Lock portion 466, in an embodiment, comprises a projection
or arm having an end that is connected proximal end 464 of clip
412b, and having a free end 467 proximal end 462, such that the
free end may be moved away from body portion 460. Free end 467 may
define an angled surface 469 for contacting, and sliding over lock
portion 444 of clip 412a.
[0165] Also depicted in FIG. 15B is an embodiment of terminal 413b
connected to a wire 414. In an embodiment, terminal 413b is
substantially similar to terminal 413a, except that terminal 413b
includes end 415 that may form a pin insertable into channel 452 of
terminal 413a. In an embodiment, end 415 may include a recess or a
slot, such that the end may be expanded or contracted.
[0166] As depicted in FIG. 15A, wires 414, including wire 414a and
414b are connected to terminals 413b and inserted into channels 468
and 470.
[0167] Referring to FIG. 16, connector 412a, specifically a 2-wire
connector 412a2, is detachably coupled to connector 412b by
inserting end 462 of connector 412b into channels 440 and 442 of
end 434 of connector 412a. As depicted, lock portion 466 engages
444, thereby detachably coupling connector 412a2 to connector 412b.
A user may disconnect connector 412a2 from connector 412b by
lifting free end 467 away from the connectors, grasping user-grip
portions 436, and pulling the connectors apart.
[0168] When coupled, each terminal 413a makes contact or electrical
connection with a corresponding terminal 413b. In an embodiment,
end 415 of terminal 413b is received by recess 452, thereby
connecting a terminal 413a with a terminal 413b. It will be
understood that other structures of terminals 413a and 413b may be
used to electrically connect connectors 412a and 412b and their
respective wires. For example, terminals 413a and 413b may comprise
male and female blade terminals, or other times of electrical
connectors and terminals, including push-on connectors, electrical
quick-disconnect connectors, and so on.
[0169] Connection of terminals 413a and 413b may occur in channels
468, 470, 440, 442, or a combination thereof.
[0170] The securement and alignment of wires 414 into connector
412b as well as the securement and alignment of wires 410 into
connector 412a, avoids or reduces torsional forces imparted by
twisting of wires 414 or 410 to be transferred from main portion
502 to any of the lighting-extension portions 404, helping keep the
structural shape of the decorative lighting, and helping to keep it
tangle free.
[0171] Consumers also benefit from the detachable feature of
connector pair 412a/412b. Whole lighting-extension portions 404 may
be replaced as an assembly by the consumer as needed by uncoupling
and coupling simple connectors, rather than replacing individual
lamp assemblies, or other wiring.
[0172] Further, from a manufacturing point of view, decorative
lighting assembly 400 provides significant savings by keeping
construction and assembly of main portion 402 separate and distinct
from lighting-extension portion 404 (icicle drop portion). In this
manner, a generic main portion 402 can be assembled, while
different lighting-extension portions 404 may be separately
manufactured, and added as needed to main portion 402.
[0173] Referring to FIGS. 14A and 14B, an embodiment of connector
412a3 is depicted. In an embodiment, connector 412a3 is
substantially the same as connector 412a2, except for channels 443
and 445. In an embodiment, channels 443 and 445 are substantially
the same as channels 440 and 442 of connector 412a2, except that
channels 443 and 445 may be slightly larger or otherwise
configured, to each accommodate two wires rather than three
wires.
[0174] In another embodiment, connectors 412a2 and 412a3 are
identical. In such an embodiment, channels, such as 440 and 443 are
large enough to receive two wires, rather than one.
[0175] In an embodiment, terminals 413, may have slightly larger
ends configured to crimp to wires, such as wires 410e, such that
one terminal 413 may crimp and connect to two wires 410e.
[0176] FIG. 17 depicts connector 412a3 coupled to connector
412b.
[0177] Referring also to FIGS. 12A and 12B, main portion 402 may,
in an embodiment, include both 2-wire connectors 412a (412a2) and
3-wire connectors 412a (412a3). In an embodiment of main portion
402 having a series of consecutive connectors 412a and an end-power
connector 408, as depicted, a first connector 412a and a last
connector 412a are both 3-wire connectors 412a3, while the
intermediate connectors 412a comprise 2-wire connectors. In an
embodiment, such a configuration is used when lamp assemblies 418
are wired electrically in series.
[0178] FIGS. 18A and 18B depict a 4-wire version of connector 412a,
namely, connector 412a4. In an embodiment, connector 412a4 is
substantially the same as connector 412a2, or the same as connector
412a2, but configured to receive four wires, two in each side.
[0179] FIG. 19 depicts connector 412a4 detachably connected to
connector 412b.
[0180] As described further below with respect to FIGS. 20 and 21,
the use of 4-wire connectors 412a facilitate electrical connection
of lamps in a parallel configuration.
[0181] Referring to FIGS. 20 and 21, an embodiment of decorative
lighting assembly 500 is depicted. Decorative lighting assembly
500, in this embodiment, is similar to decorative lighting assembly
400 in many aspects, as will be described below. However,
decorative lighting assembly 500 utilizes 4-wire connectors 412a,
facilitating an electrically parallel connection of
lighted-extension portions and lamp assemblies.
[0182] In an embodiment, decorative lamp assembly 500 includes main
portion 502 and a plurality of lighting-extension portions 504. In
an embodiment, main portion 502 extends horizontally, or
longitudinally, while lighted-extension portions 504 extend
vertically or longitudinally from main portion 502. In an
embodiment, lighted-extension portions 504 extend perpendicularly
or transversely to main portion 502, when assembled and in a
display position.
[0183] In an embodiment, main portion 502 includes power plug 506,
optional end-power connector 508, main wiring 510, and a plurality
of connectors 412a.
[0184] Power plug 506 may be substantially the same as power plug
406 as depicted and described above, but may alternatively be of
the type depicted. In an embodiment, power plug 506 may comprise
multiple pin terminals for connecting to a power source, and in an
embodiment, may also connect to a controller, or otherwise be
configured to receive control or communication signals. In an
embodiment, power plug 506 includes an attachment mechanism for
coupling to a power source, such as a threaded portion configured
to be inserted into a mating threaded cap, or other such attachment
mechanism.
[0185] End-power connector 508, when present, is configured to
connect to another decorative lighting assembly 500 having a plug
similar to power plug 506.
[0186] Main wiring 510, in an embodiment, comprises a plurality of
wires or wire segments. In an embodiment, and as depicted, main
wiring 510 includes a first set of wires 510, including: wires
510a, 510b, 510c, 510d and 510e. Wires 510 are electrically
connected to one another, and may be of a first electrical
polarity, such as DC positive or AC live or hot. Main wiring 510
also includes a second set of wires 512 electrically connected to
one another, including wires 512a, 512b, 512c, 512d, 512e and 512f
Wires 512 may be of a second polarity, such as DC negative or AC
neutral. In embodiment, a DC voltage potential exists across wires
510 and 512 when decorative lighting assembly 500 is powered; in
another embodiment, an AC voltage potential exists across wires 510
and 512 when decorative lighting assembly 500 is powered.
[0187] As depicted, ends of each of wires 510 and 512 are connected
to terminals 413a, which are configured to be received by
connectors 412a, which in the embodiment depicted, comprise 4-wire
connectors 412a4, as described above.
[0188] As such, when connected to a power source, each pair of
terminals 413a provides a voltage potential across the pair of
terminals, and therefore at each connector 412a4, such that the
connectors 412a4 are connected electrically in parallel.
[0189] Lighting-extension portions 504, in an embodiment, include
connector 412b, wires 414a and 414b and one or more lamp assemblies
518. Connectors 412b electrically and mechanically connect to
connectors 412a4 as described above with respect to FIGS.
13A-19.
[0190] Lamp assemblies 518 may comprise one, or a plurality of,
incandescent or LED lamps electrically connected in parallel or in
series. In an embodiment, lamp assemblies may comprise lighted
ornaments.
[0191] Although embodiments of decorative lighting assemblies 400
and 500 are depicted and described as including connector pairs
412a and 412b, other connectors and electrical terminals, with
other features, may alternatively be used, such as those depicted
in FIGS. 22A to 28 and those depicted in FIGS. 29A to 35.
[0192] Referring to FIGS. 22A to 28 connectors 612a and 612b with
terminals 613a and 613b that differ somewhat from connectors 412a
and 412b and terminals 413a and 413b are depicted. Connectors 612a
and 612b include nearly all of the features of connectors 412a and
412b, including locking structures, locking terminals,
user-grasping or gripping structures, wire-to-terminal connections
in the interior of the bodies of the connectors, and so on.
However, in embodiments depicted, connectors 612a and 612b include
additional features, as described further below, including
structural features that cause electrical connections of individual
wires to be made inside connector 612a, but at different planes or
heights, thereby maximizing distance between wire-to-wire and
terminal-to-terminal connection points, and minimizing the chance
of unwanted arcing between terminals of dissimilar polarities. It
will be understood that connector pair 612a/612b shares features of
connector pair 412a/412b, unless otherwise described or
depicted.
[0193] Referring specifically to FIGS. 22A and 22B, connector 612a2
is depicted. In the embodiment depicted, connector 612a2 includes
body portion 630, first end 632, and second end 634. In an
embodiment, body portion 630 includes a pair of user-gripping
portions 636 and a pair of tabs 638. User-gripping portions 636, in
an embodiment, are configured to be gripped or grasped by a user to
assist in separating connector 612a and connector 612b, and may
comprise a pair of projections joined to body portion 630 at first
end 632. User-gripping portions 636 may be configured to bend or
pivot at their respective connection points to end 632. Optional
tabs 638, when present may prevent a user's hand from slipping off
of connector 412a, when gripping portions 636 and pulling.
[0194] First end 632 of connector 612a (612a2 in this embodiment),
defines one or more openings or channels configured to receive
terminals 613, including terminals 613a and 613b, and wires, such
as 410e.
[0195] Second end 634 of connector 612a defines a receiving channel
640. Channel 640 may extend through body portion 630 to form the
channel in first end 632. In an alternate embodiment, channel 640
defines a single channel near end 634 and two channels near end
632.
[0196] As described further below, channel 640 is each configured
to receive a portion of connector 612b.
[0197] In an embodiment, body portion 630 includes lock portion
644a, comprising a pair of stops, on surface 646. Lock portion 644a
is configured to detachably couple to a lock portion of connector
612b, as will be described further below.
[0198] Still referring to FIGS. 22A and 22B, a pair of terminals
613a are attached to a pair of wires 410e, respectively. Each
terminal 613a includes an end portion 615a. End portion 615a is
configured to fit into, and in some embodiments lock to,
corresponding structure inside body portion 630, so that wires 410e
may not be easily pulled out of connector 612a after assembly. In
an embodiment, end portion 615a may generally be flat, with side
projections as depicted. Another end portion of terminal 613a is
configured to crimp to, or otherwise mechanically couple to, a
conductor portion of a wire, such as wire 410e.
[0199] As depicted, terminal 613a, and a portion of wire 410e is
inserted into connector body 630 at end 632, and into channel
640.
[0200] Referring to FIGS. 25A and 25B, an embodiment of connector
612b is depicted. In an embodiment, connector 612b is a male
connector configured to couple with a female connector, such as
connector 612a, including connector 612a2, and in some embodiments
with any of connectors 612a2 (2-wire), 612a3 (3-wire), or 612a4
(4-wire). In an embodiment, connector 612b is simply a 2-wire
connector, though in other embodiments not depicted, connector 612b
is configured to receive 3-6 wires, including 3 wires or 4
wires.
[0201] In an embodiment, connector 612b includes body portion 660,
first end 662, which is an insertion end, and second end 664 which
is a wire-receiving end. In an embodiment, second end 664 defines
flanged portion 667 that extends around a circumference of
connector 612b and has an outside diameter larger than an outside
diameter of body portion 660. Connector 612b also includes lock
portion 666, and defines channels 668 and 670, separated by wall
671. In an embodiment, channels 668 and 670 extend the entire
length of body portion 460.
[0202] First end 662, in an embodiment, is configured to be
inserted into connector 612a. In an embodiment, first end 662
includes structure defining a shape complementary to channel 640,
and thereby first end 662 is insertable into end 634 of connector
612a. In an embodiment, first end 662 comprises first side or
portion 663 and second side or portion 665 both configured to fit
into channel 640.
[0203] In an embodiment, and as depicted, each of first portion 663
and second portion 665 form side-by-side box shapes, or rectangular
cuboids. In an embodiment, second portion 665 extends further away
from end 662 as compared to first portion 663, and channels 668 and
670 extend respectively through first and second portions 663 and
665. In an embodiment, first portion 663 and second portion 665
define end diameters that are different. In one such embodiment, an
end diameter of first portion 663 is smaller than that of second
portion 665.
[0204] In an embodiment, first end 662 comprising first portion 663
and second portion 665 is narrower than second end 664, as
depicted. A narrowing between ends 662 and 664 may occur at
transition portion 673, which forms an angled portion. In an
embodiment, the narrowing of end 662 leaves space for ends 615b of
terminal 613b to be bent upwards and positioned adjacent first
portion 663 and second portion 665, respectively, as described
further below.
[0205] Lock portion 666, in an embodiment, comprises a projection
or arm that is connected proximal end 464 of clip 412b, and having
a free end 667 distal end 664, such that the free end may be moved
away from body portion 660 and positioned adjacent stop tabs 644a
of connector 612a2.
[0206] Also depicted in FIG. 25B is an embodiment of terminal 613b
connected to a wire 414. In an embodiment, terminal 413b is
substantially similar to terminal 413a, except that terminal 413b
includes end 415b that extends downwardly and away from an opposite
crimping end 611.
[0207] In an embodiment, a terminal 613b attached to a wire 414,
such as wire 414a, is inserted into channel 668, such that end 615b
projects outside channel 668 at first end 662, then is bent around
an edge of first end 662, projecting upwardly, parallel to, and
adjacent to, an outside surface of first portion 663 (not depicted,
but substantially the same as depicted for terminal 613b and second
end 665, which is depicted). In an embodiment, a portion of end
615b contacts ridge 673, and is bent at another point so that the
tip of end 615b projects slightly outwardly and away from the
outside surface of first portion 663.
[0208] Similarly, in an embodiment, a terminal 613b attached to a
wire 414, such as wire 414b, is inserted into channel 670, such
that end 615b projects outside channel 670 at second end 664, then
is bent around an edge of second end 664, projecting upwardly,
parallel to, and adjacent to, an outside surface of second portion
665. In an embodiment, end 615b is bent 180.degree.. In an
embodiment, a portion of end 615b contacts ridge 673, and is bent
at another point so that the tip of end 615b projects slightly
outwardly and away from the outside surface of second portion 665.
The bend at the tip of end 615b may assist in securing terminal
613b in connector 412a2.
[0209] Referring to FIG. 26, connector 612a, specifically a 2-wire
connector 612a2, is detachably coupled to connector 612b by
inserting end 662 of connector 612b into channel 640 of end 634 of
connector 612a. As depicted, lock portion 666 engages lock portion
stop tabs 644a, thereby detachably coupling connector 612a2 to
connector 612b. A user may disconnect connector 612a2 from
connector 612b by lifting free end 667 away from the connectors,
grasping user-grip portions 636, and pulling the connectors
apart.
[0210] When coupled, each terminal 613a makes contact or electrical
connection with a corresponding terminal 613b. In an embodiment, an
exposed end 615b of terminal 613b (the end or portion adjacent an
outside surface of first portion 663 or second portion 665) is
positioned adjacent a corresponding end 615a of a terminal 613a,
thereby making an electrical connection between pairs of terminals
613a and 613b inside connector 612a2.
[0211] Because first portion 663 is shorter, or does not project as
far from end 664 as compared to second portion 664, terminal 613a
and terminal 613b adjacent first portion 663 make electrical
connection closer to second end 664 as compared to terminals 613a
and 613b adjacent second portion 665. This structure that results
in electrical contact points positioned at different longitudinal
or vertical positions within connector 612a2 aids in reducing
accidental arcing between terminals adjacent first portion 663 and
second portion 665.
[0212] FIGS. 32C and 33B depict coupling of connectors 712a and
712b, which are similar to connectors 612a and 612b, provide cross
sectional views depicting the concept of longitudinally shifted
electrical connection points.
[0213] Referring to FIGS. 23A and 23B, an embodiment of connector
612a3 is depicted. In an embodiment, connector 612a3 is
substantially the same as connector 612a2. In an embodiment,
channel 640 may be modified to accommodate three wires instead of
two wires.
[0214] FIGS. 24A and 24B depict a 4-wire version of connector 612a,
namely, connector 612a4. In an embodiment, connector 612a3 is
substantially the same as connector 612a2. In an embodiment,
channel 640 may be modified to accommodate four wires instead of
two wires.
[0215] FIGS. 26-28 depict connectors 612a2, 612a3, and 612a4
detachably connected to connectors 412b, respectively.
[0216] Referring to FIGS. 29A to 35, another embodiment of a pair
of connectors similar to connectors 412a/412b and 612a/612b, is
depicted. Connector pair 712a and 712b is very similar to connector
pair 612a/612b, sharing features of connector pair 612a/612b,
unless otherwise described or depicted.
[0217] Referring specifically to FIGS. 29A, 29B and 29C, connector
712a2 is depicted. In the embodiment depicted, connector 712a2
includes body portion 730, first end 732, and second end 734.
[0218] First end 732 of connector 712a (712a2 in this embodiment),
defines one or more openings or channels 715 configured to receive
terminals 713, including terminals 713a and 713b, and wires, such
as 410e. In the embodiment depicted, first end 732 defines two
channels, channels 715a and 715b, separated by wall 717. Wall 717,
in an embodiment, projects only partially into body portion 730,
and assists in keeping wires and terminals positioned inside body
portion 730.
[0219] Second end 734 of connector 712a2 defines a receiving
channel 740. Channel 740 may extend through body portion 730 to
channels 715a and 715b. In an alternate embodiment, body portion
730 and its second end 734 form only a portion of a single channel
740, and do not define separate, additional channels 715a and 715b.
As described further below, channel 740 is each configured to
receive a portion of connector 612b.
[0220] Second end 732, in an embodiment, also includes internal
surface structure 733 for aligning and positioning 712b in
receiving channel 740. In an embodiment, internal surface structure
733 includes vertical or longitudinal alignment ridge 735
projecting radially inward and extending longitudinally,
vertically, or axially (with respect to an inserted wire axis).
Alignment ridge 735 may be configured to be received by a
corresponding slot or channel 737 on connector 712b. In an
embodiment, alignment structure 733 may also include recesses in an
inside surface of body portion 730.
[0221] In an embodiment, second end 734 of body portion 730 defines
one or more lock openings 739, each configured to receive a portion
of a locking projection or arm 741 of connector 712b, as described
further below, for locking connector 712b into connector 712a2.
[0222] A pair of terminals 613a is attached to a pair of wires
410e, respectively. Each terminal 613a includes an end portion
615a. End portion 615a is configured to fit into, and in some
embodiments lock to, corresponding structure inside body portion
730, so that wires 410e may not be easily pulled out of connector
712a2 after assembly. In an embodiment, end portion 615a may
generally be flat, with side projections as depicted. Another end
portion of terminal 613a is configured to crimp to, or otherwise
mechanically couple to, a conductor portion of a wire, such as wire
410e.
[0223] As depicted, terminals 613a, and a portion of wires 410e are
inserted into connector body 730 at end 732, and into and through
channels 715a and 715b, and into channel 740.
[0224] Referring to FIGS. 32A, 32B and 32C, an embodiment of
connector 712b is depicted. In an embodiment, connector 712b is a
male connector configured to couple with a female connector, such
as connector 712a, including connector 712a2, and in some
embodiments with any of connectors 712a2 (2-wire), 712a3 (3-wire),
or 712a4 (4-wire). In an embodiment, connector 712b is simply a
2-wire connector, though in other embodiments not depicted,
connector 712b is configured to receive 3-6 wires, including 3
wires or 4 wires.
[0225] In an embodiment, connector 712b includes body portion 760,
first end 762, which is an insertion end, and second end 764 which
is a wire-receiving end. In an embodiment, second end 764 defines
flanged portion 767 that extends around a circumference of
connector 612b and has an outside diameter larger than an outside
diameter of body portion 760. In an embodiment, connector 712b also
includes a pair of lock portions 741, which may be arms attached
proximal second end 734 having a free end 743. Free end 743 may
include end portion 745 configured to be received in lock openings
739 of connector 712a2.
[0226] In an embodiment, 712a2 and body portion 730 defines
channels 768 and 770, separated by wall 771. In an embodiment,
channels 668 and 670 extend the entire length of body portion
460.
[0227] First end 762, in an embodiment, is configured to be
inserted into connector 612a. In an embodiment, first end 762
includes structure defining a shape complementary to channel 740,
and thereby first end 762 is insertable into end 734 of connector
712a2. In an embodiment, first end 762 comprises first side or
portion 763 and second side or portion 765 both configured to fit
into channel 740.
[0228] In an embodiment, and as depicted, each of first portion 763
and second portion 765 form side-by-side box shapes, or rectangular
cuboids. In an embodiment, second portion 765 extends further away
from end 762 as compared to first portion 763, and channels 768 and
770 extend respectively through first and second portions 763 and
765. In an embodiment, first portion 763 and second portion 765
define end diameters that are different. In one such embodiment, an
end diameter of first portion 763 is smaller than that of second
portion 665.
[0229] In an embodiment, first end 762 comprising first portion 763
and second portion 765 is narrower than second end 664, as
depicted. A narrowing between ends 762 and 764 may occur at
transition portion 773, which forms an angled portion. In an
embodiment, the narrowing of end 762 leaves space for ends 615b of
terminal 613b to be bent upwards and positioned adjacent first
portion 763 and second portion 765, respectively, as described
further below.
[0230] In an embodiment, a terminal 613b attached to a wire 414,
such as wire 414a, is inserted into channel 768, such that end 615b
projects outside channel 768 at first end 762, then is bent around
an edge of first end 762, projecting upwardly, parallel to, and
adjacent to, an outside surface of first portion 763 (not depicted,
but substantially the same as depicted for terminal 613b and second
end 765, which is depicted). In an embodiment, a portion of end
615b contacts ridge 773, and is bent at another point so that the
tip of end 615b projects slightly outwardly and away from the
outside surface of first portion 763.
[0231] Similarly, in an embodiment, a terminal 613b attached to a
wire 414, such as wire 414b, is inserted into channel 770, such
that end 615b projects outside channel 770 at second end 764, then
is bent around an edge of second end 764, projecting upwardly,
parallel to, and adjacent to, an outside surface of second portion
765. In an embodiment, a portion of end 615b contacts ridge 773,
and is bent at another point so that the tip of end 615b projects
slightly outwardly and away from the outside surface of second
portion 765. The bend at the tip of end 615b may assist in securing
terminal 613b in connector 712a2.
[0232] Referring to FIGS. 33A and 33B, a connector 712a,
specifically a 2-wire connector 712a2, is detachably coupled to
connector 712b by inserting end 762 of connector 712b into channel
740 of end 734 of connector 712a2. As depicted, end portions 745,
which project transversely to body portion 730, are received by
lock openings 739, thereby locking connector 712b to connector
712a2. In this embodiment, only a small portion of free end 743 of
arm 741, i.e., a portion of end 745 projects out of a lock opening
739, such that a user cannot easily disconnect or detach connector
712b from connector 712a2, without using a tool of some sort to
press end 745 into channel 740 before pulling apart. Such a
configuration ensures that the connectors are not easily detached
from one another, thereby exposing potentially live electrical
conductors. Such a configuration enhances the safety of the
decorative light assembly, such as decorative light assemblies 400
and/or 500.
[0233] When coupled, each terminal 613a makes contact or electrical
connection with a corresponding terminal 613b. In an embodiment, an
exposed end 615b of terminal 613b (the end or portion adjacent an
outside surface of first portion 663 or second portion 665) is
positioned adjacent a corresponding end 615a of a terminal 613a,
thereby making an electrical connection between pairs of terminals
613a and 613b inside connector 712a2.
[0234] Similar to connector pair 612a2/612b, because first portion
763 is shorter, or does not project as far from end 764 as compared
to second portion 764, terminal 613a and terminal 613b adjacent
first portion 763 make electrical connection closer to second end
764 as compared to terminals 613a and 613b adjacent second portion
765. This structure that results in electrical contact points
positioned at different longitudinal or vertical positions within
connector 712a2 aids in reducing accidental arcing between
terminals adjacent first portion 763 and second portion 765. As
depicted, electrical connection between first portion 763 terminals
occurs at or above plane P1, while electrical connection between
first portion 765 terminals occurs at or above plane P2. In an
embodiment, and as depicted, plane P1 is a horizontal plane defined
at an end of first portion 763, while plane P2 is a horizontal
plane defined at an end of second portion 765.
[0235] Another feature of connector pair 712a/712b is that wall 771
provides an insulative barrier between terminal ends 615a of first
and second portions 763 and 765, thereby reducing the chance of
arcing between terminals of opposite polarity.
[0236] Referring to FIGS. 30A and 30B, an embodiment of connector
712a3 is depicted. In an embodiment, connector 612a3 is
substantially, or exactly, the same as connector 712a2. In an
embodiment, channel 740 may be modified, including enlarging body
portion 730, to accommodate three wires instead of two wires.
[0237] FIGS. 31A and 31B depict a 4-wire version of connector 712a,
namely, connector 712a4. In an embodiment, connector 712a4 is
substantially the same as connector 712a2. In an embodiment,
channel 740 may be modified to accommodate four wires instead of
two wires.
[0238] FIGS. 34-35 depict connectors 712a2, 712a3, and 712a4
detachably connected to connectors 712b, respectively.
[0239] As described above in detail, any of connector pairs
412a/412b, 612a/612b or 712a/712b may be used with decorative
lighting assemblies 400 and 600.
[0240] Referring to FIG. 36, an embodiment of reinforced
decorative-lighting wire or cord 1100 is depicted. In an
embodiment, reinforced decorative-lighting wire 1100 includes one
or more reinforcing strands or threads 1102, one or more conductor
strands 1104, and insulating layer or jacket 1106. Conductor
strands 1104 may form one or more layers, such as the depicted
first conductor layer 1108 and second conductor layer 1110. As will
be described further below, reinforcing strands 1102 and conductor
strands 1104 may be arranged in a variety of manners, and in a
variety of quantities, dependent upon a number of factors,
including desired wire properties, including, but not limited to,
tensile strength, resistivity and conductivity.
[0241] Reinforced decorative-lighting wire 1100 may comprise a
variety of sizes, resistances, and ampacities, and may be described
in terms of electrically-equivalent wire gauge standards, e.g., 20
AWG (American Wire Gauge), 22 AWG, 24 AWG, etc. For example, in an
embodiment, wire 1100 may comprise a conductive equivalent to a
wire normally described as a 22 AWG wire having an equivalent cross
sectional area of conductive copper of approximately 0.326 mm2 and
having a typical resistance of approximately 52.96 ohms/km, though
the overall diameter of the complete wire may be greater than a
standard 22 AWG wire due to the additional reinforcing strands.
[0242] Reinforced decorative-lighting wire 1100 may also be
described in terms of other equivalent wire standards, such as
Underwriter's Laboratories Standard UL 62 insofar as it pertains to
decorative-lighting wire, including standards directed to Type XTW
or Type CXTW as typically used in decorative-lighting applications.
For example, an embodiment of a reinforced decorative-lighting wire
1100 may be designed to include characteristics equivalent to
selected characteristics of an 18, 20 22, 25, or 25 AWG CXTW wire,
particularly conductive characteristics such as DC resistance per
conductor strand, and insulative characteristics.
[0243] As depicted in FIG. 36, an embodiment of reinforced
decorative-lighting wire 1100 comprises a single reinforcing strand
1102, and multiple conductor strands 1104. In an embodiment,
conductor strands 1104 form two layers: first conductor layer 1108
and second layer 1110, though it will be understood that conductors
1104 may form one, two, or more than two layers. Layers 1108 and
1110 form a stranded conductor of reinforced wire 1100. A
reinforced wire 1100 having the stranded conductor comprising
multiple conductor strands 1104 may also be referred to as a
"single" conductor reinforced wire 1100 to differentiate from
standard twisted pairs of wires typically used in decorative
lighting. However, it will be understood that in some applications,
pairs of single-conductor reinforced wires 1100 may be twisted
about one another to form reinforced twisted-pair wire sets.
[0244] In an embodiment, and as depicted, reinforcing strand 1102
extends axially along a length of wire 1100, and along central wire
Axis A, surrounded by, or adjacent to, conductor strands 1104. In
an embodiment, reinforcing strand 1102 is generally located
radially at a center of wire 1100.
[0245] Reinforcing strand 1102 may define a generally cylindrical
shape defining a circular cross-sectional area, though the
cross-sectional area may define other shapes, such as square, oval,
rectangular, and so on. In other embodiments, and as will be
described further below with respect to FIGS. 4B and 9A-13B,
reinforcing strand 1102 may define a generally circular
cross-sectional shape prior to assembly into wire 1100, but then
define a different, shape, such as an asymmetrical shape, after a
manufacturing assembly process.
[0246] In an embodiment, central reinforcing strand 1102 comprises
one or more fibers or strands of fibrous reinforcing material. In
the depicted embodiment, reinforcing strand 1102 comprises a single
strand or fiber of reinforcing material. In other embodiments,
reinforcing strand 1102 comprises multiple strands of reinforcing
material that may comprise twisted strands, threads or fibers such
that reinforcing strand 1102 comprises a yarn of multiple strands
or fibers.
[0247] In the embodiment depicted, reinforcing strand 1102
comprises a single 1500 Denier fiber having an outside diameter of
approximately 0.45 mm. In another embodiment, reinforcing strand
1102 comprises a fiber ranging from 500 Denier to 2500 Denier. In
other embodiments, reinforcing strand 1102 may comprise a larger or
smaller diameter and/or greater or lesser Denier fiber depending on
the properties of the reinforcing material and desired reinforcing
properties. In an embodiment, reinforcing strand 1102 comprises a
single or multi-fiber strand sized to be within the range of 1000
to 1500 Denier. Reinforced wire 1100 with reinforcing strands 1102
comprising such a size may provide appropriate reinforcing strength
for wires 1100 that most decorative lighting applications that
would typically use an 118-24 AWG standard wire.
[0248] The reinforcing material of reinforcing strand 1102 may
comprise a generally non-conductive or nonmetallic material, such
as a plastic or polymer, including a polyester or polyethylene (PE)
material. In one such embodiment, reinforcing strand 1102 comprises
a polyethylene terephthalate (PET) material. Other reinforcing
materials may include, though will not be limited to, polystyrene,
polyvinyl chloride (PVC), polyamide (PA), and so on. Reinforcing
strand 1102 may consist entirely or substantially of a
non-conductive or nonmetallic material, such as PET, though in some
embodiments, reinforcing strand 1102 may comprise a composite
material. Such a composite material may comprise a non-conductive
material, such as PET, as well as some other conductive,
partially-conductive, or other non-conductive material.
[0249] In an embodiment, and as depicted, reinforcing strand 1102
comprises a substantially solid structure in cross section
(radially), as compared to a hollow core strand such as a pipe or
other annular shape. Further, in an embodiment, reinforcing strand
1102 comprises the same material continuously along its axial
length. In an embodiment, reinforcing strand 1102 may have a
hardness that is less than a hardness of a conductor strand 1104.
In an embodiment, reinforcing strand 1102 has a Rockwell hardness
of R117.
[0250] In an embodiment, reinforcing strand 1102 comprises
primarily a PET material, having a specific gravity ranging from
1380-1405 kg/m3, and a melting point of 200-250 degrees Celsius. In
other embodiments, reinforcing strand 1102 comprises a polymer
having a specific gravity that ranges from 1000-2000 kg/m3, and a
melting point of 1150-300 degrees Celsius. Material in such a range
may provide an appropriate balance of strength and flexibility for
decorative light string applications. Further, as will be explained
further below, such properties allow for deformation of reinforcing
strand 1102 during the manufacturing assembly process.
[0251] In an embodiment, wherein reinforcing strand 1102 comprises
primarily a PET material, strand 1102 comprises an elongation at
break of 300%, or may comprise an elongation range of 200% to 400%,
and a tensile strength of 55 MPa (7,977 psi). Herein, tensile
strength refers to its ordinary meaning as understood in the field
of conductive wires, including tensile strength being the maximum
amount of stress that wire 1100 can withstand before failing or
breaking, while being stretched or pulled axially along axis A
(along a length of wire 1100) by opposing axial forces labeled F1
and F2 in FIG. 36.
[0252] In another embodiment wherein strand 1102 comprises a PET
material, an elongation property of strand 1102 ranges from 200% to
400%, and a tensile strength ranges from 45 to 65 MPa. In an
embodiment, the elongation of strand 1102 may be less than an
elongation of conductor strand 1104. In another embodiment, the
elongation of a strand 1102 may be approximately the same as, or
greater than, a conductor strand 1104. In an embodiment, the
tensile strength of a strand 1102 may be less than the tensile
strength of a conductor strand 1104. In another embodiment, the
tensile strength may be approximately the same as, or greater than,
a conductor strand 1104. In an embodiment, the elongation of a
strand 1102 may be less than the overall elongation of reinforced
wire 1100. In another embodiment, the elongation may be
approximately the same as, or greater than, reinforced wire 1100.
In an embodiment, the tensile strength of a strand 1102 may be less
than the overall tensile strength of reinforced wire 1100. In
another embodiment, the tensile strength may be approximately the
same as, or greater than, reinforced wire 1100.
[0253] Conductor strands 1104 may comprise any number of known
conductive materials, including metals and metal alloys, such as
copper, aluminum, steel, nickel, aluminum, and so on. Embodiments
of alloys may include copper aluminum alloy, copper steel alloy,
and so on. In an embodiment, one or more conductor strands comprise
soft-annealed copper strands, which may be uncoated, or in some
embodiments, coated with tin. Conductor strands 1104 comprised of
copper, including comprised primarily of copper, provide not only
superior tensile strength, but also superior ductility properties
as compared to conductor strands 1104 comprising other metals, such
as aluminum. A relatively higher ductility deriving from the use of
copper conductor strands 1104, in combination with a polymer
reinforcing strand 1102, allows deformation, particularly
elongation when wire 1100 is subjected to tensile stress. Such a
feature provides advantages in decorative lighting. In contrast,
stranded conductors commonly used in overhead power line
applications typically rely on aluminum conductors having low
ductility, resulting in low elongation. In such an application,
sagging of the heavy power lines/conductors is a concern, and the
desirable low ductility or inability to elongate, is an important
consideration. On the other hand, in decorative lighting, the
ability of a wire to deform or elongate (relatively high ductility,
e.g., the ductility of copper) may be advantageous. For example,
when subjected to a tensile stress or force, wire 1100 may elongate
rather than break, thereby preventing exposure of conductor strands
1104, and preventing a potentially hazardous situation. Elongation
properties of reinforced decorative lighting wire 1100 are
discussed further below.
[0254] Further, properties of high tensile strength, flexibility,
and the ability to stretch or elongate when subjected to axial
pulling may be advantageous for reinforced wire 1100 when applied
to a decorative lighting apparatus. Unlike cables and wires used in
overhead power transmission applications, wires used in decorative
lighting applications tend to be supported over much of their
length. For example, decorative light strings applied to trees,
such as Christmas trees, are generally affixed to the branches of
the tree and are well supported, with only very short runs of wire
that are unsupported. Conversely, in overhead power transmission
applications, extremely long lengths of wire are unsupported
between power poles. Consequently, the materials and properties of
cables and wires for such power transmission applications may be
significantly different than those of reinforced decorative
lighting wire 1100 as described herein.
[0255] In addition to ductility, tensile strength of conductor
strands 1104 and associated conductor layers 1106 and 1108, as well
as overall tensile strength of reinforced wire 1100 remains a
consideration. In an embodiment of reinforced wire 1100 comprising
soft-annealed copper conductor strands 1104, a tensile strength of
each copper strand 1104 will have a higher tensile strength, for
example, ranging from 200-250 N/mm2, as compared to aluminum
alloys, for example, 100 N/mm2. In an embodiment, each conductor
strand 1104 has a tensile strength that is less than a tensile
strength of reinforcing strand 1102. In one such embodiment,
conductor strands 1104 comprise a copper material, and reinforcing
strand 1102 comprises PET.
[0256] In an embodiment, each conductor strand 1104 comprises a
continuous, solid-core strand, though the entire wire 1100
comprises a multi-stranded wire. In other embodiments, each
conductor strand 1104 may comprise multiple, individual strands. In
an embodiment, all strands have approximately the same average
diameter.
[0257] In a stranded conductor embodiment of wire 1100, individual
conductor strands comprise 27 to 36 AWG copper conductor strands.
In an embodiment, conductor strands comprise 27 AWG strands. In an
embodiment, conductor strands comprise copper strands having
diameters measuring, on average, 0.16 mm (34 AWG, or 0.16 AS). In
other embodiments, copper strands comprise other diameters,
including strands that have average diameters of 0.16 mm, or
average diameters of approximately 0.16 mm, such as 0.16 mm+/-10%.
In another embodiment, average diameters of copper strands used in
a single wire 1100 range from 0.15 mm to 0.16 mm, or in another
embodiment 0.25 mm+/-10%. In decorative lighting applications, a
relatively wide range or tolerance in strand diameter may be
sufficient due to a common practice of operating decorative light
strands at currents significantly below maximum safe ampacity
limits. Conductor strands 1104 may comprise copper strands
complying with ASTM B 3-90 standards.
[0258] Conductor strands 1104 extend axially along Axis A, and may
or may not be twisted about reinforcing strand 1102 or other
conductor strands 1104.
[0259] Conductor strands 1104 may generally be cylindrical,
presenting a generally circular cross section, though in other
embodiments, each strand 1104 may present other cross-sectional
shapes.
[0260] The number of conductor strands 1104 may vary based on a
combination of factors, including desired conductive properties,
and mechanical design characteristics. For example, for a 22 AWG
equivalent wire, which in the decorative lighting industry may
typically comprise 116 copper strands, reinforced
decorative-lighting wire 1100 may also comprise 116 conductor
strands. In another embodiment reinforced wire 1100 may be
equivalent to 25 AWG in its current-carrying capability (maximum of
0.73 A), and may comprise 8 conductor strands, which in an
embodiment comprises (8) 0.16 mm diameter strands. In other
embodiments of 25 AWG equivalent wire, reinforced wire 1100 may
include 8-10 conductor strands 1104; in an embodiment, each
conductor strand 1104 may have a diameter averaging 0.16 mm, or
alternatively, 0.157-0.154 mm.
[0261] In other embodiments of wire 1100, which in an embodiment
may comprise 24 AWG equivalent wire, reinforced wire 1100 may
include 8 conductor strands 1104; in an embodiment, each conductor
strand 1104 may have a diameter averaging 0.16 mm, or
alternatively, 0.157-0.154 mm.
[0262] In embodiments, the above configurations of strands 1104 may
be combined with polymer reinforcing strands 1102 sized to fall
within a range of 1000 to 1500 Denier.
[0263] The number of conductor strands 1104 may be greater or fewer
than that of an equivalent wire having similar conductive
properties, though it will be understood that particular
embodiments of wire 1100 are intended to match the electrical or
conductive properties of equivalent standard wires described by the
American Wire Gauge standard, e.g., 22 AWG wire, such that even if
the number of strands is not equal to the number of strands in an
equivalent standard wire, the size of each conductor strand 1104
will be increased or decreased to maintain electrical equivalence.
An embodiment of a reinforced decorative wire 1100 having
electrical properties similar or equivalent to a 22 AWG wire will
be described below to further clarify and emphasize the above.
[0264] Referring also to FIG. 37A and FIG. 37B, in the embodiment
depicted, first conductor layer 1108 is formed of multiple
conductor strands 1104 twisted about centrally-positioned
reinforcing fiber 1102. In the depicted embodiment, first conductor
layer 1108 comprises five conductor strands 1104. In other
embodiments, first conductor layer 1108 comprises more or fewer
strands. In an embodiment, the number of strands 1104 in first
conductor layer 1108 ranges from three strands to eight
strands.
[0265] Strands 1104 extend axially along Axis A and in an
embodiment, are twisted about reinforcing strand 1102. As depicted,
strands 1104 are helically twisted about reinforcing strand 1102 in
a counter-clockwise direction, though in other embodiments, strands
1104 may be twisted or wrapped about reinforcing wire 1102 in a
clockwise direction.
[0266] Central axes of conductor strands 1104 are depicted in FIGS.
3, 4A and 4B by arrows B1'-B5 (first layer 1108) and C1-C11 (second
layer 1110).
[0267] The twist or "pitch" of conductor strands 1104 may be
defined by a "length of lay", or the length of conductor strand
1104 required to turn a full rotation, or turn 360 degrees. As
compared to standard gauge wire having equivalent electrical
properties, wire 1100 of the claimed invention may have lesser
lengths of lay when the same number of conductor strands 1104 are
used. For example, in an embodiment of a 22 AWG equivalent wire, a
length of lay of a conductor strand 1104 of first layer 1108 is
approximately 118.5 mm, as compared to approximately 32 mm for an
equivalent standard 22 AWG wire commonly used for decorative
lighting. The additional twists per unit of length, or decreased
length of lay provides axial reinforcing strength in addition to
the reinforcing strength added by reinforcing strands 1102.
[0268] Furthermore, the shorter length of lay may allow further
stretching and elongation of wire 1100 without breakage when
subjected to axial opposing forces, such as F1 and F2 as depicted
in FIG. 36.
[0269] In an embodiment, conductor strands 1104 of layer 1108 each
have an approximately equal length of lay, though in other
embodiments, including some described further below, conductor
strands 1104 may have different lengths of lay.
[0270] Additionally, unlike typical wires used in decorative
lighting that comprise only conductive strands, i.e., no
reinforcing strand, the use of one or more reinforcing strands 1102
in wire 1100 may allow for some slight radial compression of
strands 1102 by conductor strands 1104 when wire 1100 is subjected
to axial forces. This provides the added advantage of allowing wire
1100 to elongate even further than a typical decorative lighting
wire of a similar wire gauge and ampacity.
[0271] Second conductor layer 1110 is formed on first conductor
layer 1108, and also comprises a plurality of conductor strands
1104. In an embodiment, and as depicted, second conductor layer
1110 comprises eleven conductor strands 1104. In other embodiments,
second conductor layer 1110 comprises more or fewer strands 1104.
In an embodiment, the number of conductor strands 1104 in second
layer 1110 ranges from four strands to 30 strands.
[0272] Strands 1104 extend axially along Axis A, and are adjacent
strands 1104 of first layer 1108. In an embodiment, strands 1104 of
second layer 1110 are adjacent to, and twisted about first layer
1108. As depicted, strands 1104 are twisted about layer 1108 and
its strands 1104 in a counter-clockwise direction. As such, in an
embodiment, conductor strands 1104 of second conductor layer 1110
twists in the same direction as the direction that conductor
strands 1104 of second conductor layer 1108 twist. In other
embodiments, strands 1104 may be twisted over layer 1108 in a
clockwise direction, and may twist in a direction opposite to a
twist direction of first conductor layer 1110. Strands 1104 forming
conductor layer 1108 generally are positioned adjacent one
another.
[0273] In an embodiment, conductor strands 1104 of layer 1110 each
have an approximately equal length of lay, though in other
embodiments, including some described further below, conductor
strands 1104 may have different lengths of lay.
[0274] Insulating layer (or jacket) 1106 wraps about second
conductive layer 1110, covering and insulating conductor strands
1104 and reinforcing strand 1102. Insulating layer 1106 may
comprise any of a variety of known insulating materials, including
polymers such as PVC, PE, thermoplastics, and so on. In addition to
providing insulative properties, insulating layer 1106 may add
mechanical strength through its other properties. In an embodiment,
insulating layer 1106 has a minimum elongation percentage of 150%.
In an embodiment, insulating layer 1106 comprises a polymer having
a composition different than the polymer comprising reinforcing
strand 1102.
[0275] Referring still to FIGS. 6, 7A and 7B, in an embodiment,
wire 1100 comprises a reinforced 22 AWG-electrically-equivalent
wire comprising a single reinforcing strand 1102 extending axially
along a center of wire 1100, surrounded by 116 twisted conductor
strands 1104, and overlaid with an insulating jacket layer 1106.
The 116 conductor strands 1104 comprise first conductive layer
1108, consisting of 5 conductive strands 1104, and second
conductive layer 1110, consisting of 11 conductive strands 1104. In
an embodiment, reinforcing strand 1102 comprises PET material in
the form of a 11500 Denier strand; conductive strands 1104 comprise
primarily copper; and insulating layer 1106 comprises PVC.
[0276] Each conductive strand 1104 defines an approximately 0.16 mm
diameter, circular or round wire, such that the equivalent
cross-sectional area of the conductive portion of wire 1100 is
approximately the same as a standard 22 AWG wire, also denoted as
116/0.16 AS, meaning 116 strands of 0.16 mm diameter conductor
strands. In this embodiment, the resistivity ranges from 54 to 57
ohms/km. In an embodiment, the resistivity is 56.8 ohms/km or less.
In an embodiment, the resistivity is substantially 55 ohms/km.
[0277] The length of lay, sometimes referred to as lay of strand,
of each conductor strand 1104 of first layer 1108, in an embodiment
is 32 mm or less. In an embodiment, the length of lay of conductor
strand 1104 of first layer 1108 ranges from 15 mm to 25 mm. In an
embodiment, the length of lay of conductor strands 1104 of first
layer 1108 is approximately 18.5 mm. In an embodiment the length of
lay of all conductor strands 1104 of first layer 1108 are
approximately the same. In an embodiment, a lineal length of each
strand per unit length is within 5% of an average lineal length
(note: the lineal length of a strand will be longer than a unit
length due to the helical twisting of a wire, e.g., a 1 foot length
of wire 1100 will include strands 1104 having lineal lengths longer
than 1 ft. In other embodiments, the lineal length of individual
strands 1104 may vary more substantially per unit length of wire
1100, particularly when lengths of lay of individual strands 1104
are allowed to vary from strand to strand.
[0278] The length of lay of conductor strands 1104 of second
conductive layer 1110 may be the same as conductor strands 1104 of
first conductor layer 1108, or in some embodiments, may be
different. In an embodiment a length of lay of conductor strands
1104 of second layer 1110 is 32 mm or less. In an embodiment, the
length of lay of conductor strand 1104 of second layer 1110 ranges
from 15 mm to 25 mm. In an embodiment, the length of lay of
conductor strands 1104 of second layer 1110 is substantially 18.5
mm. In an embodiment, lengths of lay of conductor strands 1104 of
both layers 1108 and 1110 are, on average, approximately 18.5 mm.
In an embodiment, the direction of twisting is the same, as
depicted in FIG. 36.
[0279] In an embodiment, including an embodiment of 22 AWG
reinforced wire 1100, insulation layer 1106, comprising primarily
PVC material, has a minimum thickness of 0.69 mm. In an embodiment,
insulation 1106 comprises a thickness ranging from 0.69 mm to 1.0
mm. In an embodiment, an average thickness of insulating layer 1106
has an average thickness of 0.76 mm or greater. In one such
embodiment, insulating layer 1106 has an average thickness of 0.84.
In an embodiment insulating layer 1106 has an insulation resistance
of at least 225 M.OMEGA./Kft.
[0280] In an embodiment, the overall diameter of wire 1100 in 22
AWG ranges from 2.40 to 2.70 mm. In an embodiment, an average
overall diameter is approximately 2.6 mm; in an embodiment, an
average overall wire 1100 diameter is 101 mil.
[0281] With respect to elongation, in an embodiment, wire 1100 has
an elongation of 150% or greater. In an embodiment, the elongation
of wire 1100 ranges from 150% to 400%. In one embodiment, wire 1100
exhibits 300% elongation, significantly longer than standard,
all-copper multi-stranded 22 AWG CXTW wire.
[0282] With respect to tensile strength, embodiments of wire 1100
have an improved tensile strength, which in one embodiment includes
a tensile strength of 1,500 PSI or greater. In an embodiment, the
tensile strength ranges from 1,500 PSI to 4,000 PSI, in another
embodiment, the tensile strength ranges from 2,500 to 3,500 PSI.
Such a range may provide sufficient strength for various decorative
lighting applications, including trees, net lights, sculptures, and
so on. In some applications where wires are affixed tightly to
supporting structure, such as trees of metal frames, a required
tensile strength may be on the lower end of the range, while wires
of light strings that are not affixed to, or are less supported,
may require higher tensile strength due to possible pulling or
yanking by a user.
[0283] Another method of describing and measuring "strength" of a
wire, including a reinforced wire 1100, and as commonly used in
decorative lighting is to measure an axially-applied pulling force
required to cause the wire to begin to break, such that an outer
insulation shows breakage, or an inner conductor shows breakage. In
an embodiment, reinforced wire 1100 may withstand axial pulling
forces of various ranges depending on the particular reinforced
wire 1100 configuration.
[0284] In an embodiment, reinforced wire 1100 may withstand a
minimum axially-applied pulling force ranging from 22 lbf to 46
lbf. In one such embodiment, reinforced wire 1100 comprises an
ampacity equivalent to a 22 AWG wire, and can withstand a minimum
22.4 lbf without breaking; in another embodiment, reinforced wire
1100 comprises an ampacity equivalent to a 20 AWG wire, and can
withstand a minimum 30 lbf without breaking; in another embodiment,
reinforced wire 1100 comprises an ampacity equivalent to a 18 AWG
wire, and can withstand a minimum 46 lbf without breaking.
[0285] In another embodiment, reinforced wire 1100 comprises 7-10
conductor strands 1104 defining a range of minimum axial pulling
force ranging from 22.4 lbf to 46 lbf. In one such embodiment,
reinforced wire 1100 comprises 8 conductor strands and has a
minimum axial pulling force at breakage of 46 lbf; in one such
embodiment, each conductor strand 1104 may have an average diameter
in the range of 0.15 mm to 0.17 mm; alternatively, each conductor
strand 1104 may have an average diameter of 0.154 mm to 0.157 mm.
Such ranges accommodate expected current flows in various
decorative lighting applications, while offering substantial
overall tensile strength.
[0286] In an embodiment, wire 1100 includes a 1500 Denier PET
reinforcing strand 1102 extending axially along Axis A, 16 copper
conductor strands of 0.16 mm average diameter (5 first layer 1108
strands and 11 second layer 1110 strands) having a 55 .OMEGA./km
resistivity, and insulating layer 1106 of PVC material. In one such
embodiment, elongation is greater than 300% (in an embodiment is
306%), with a tensile strength of 2800 PSI, requiring a force of
approximately 21 kg to break. Such a wire may be used as a
substitute for standard 22 AWG wire, including 22 AWG CXTW wire for
improved decorative-lighting applications.
[0287] Referring to FIG. 37B, the wire 1100 of FIGS. 36 and 37A is
depicted again, but in this case, the configuration of wire 1100,
namely the relative positions of conductor strands 1104 and
reinforcing strand 1102, are somewhat different. In an embodiment,
because of the malleable properties of reinforcing strand 1102,
including the fibrous nature, pliability, and so on, during
manufacturing of wire 1100, reinforcing strand 1102 may be deformed
somewhat, which in turn, may cause first and second layer strands
1108 and 1110 to move relative to one another, and relative to
reinforcing strand 1102. As depicted in FIG. 37B, at a particular
cross section, reinforcing strand 1102 does not comprise a circular
cross section, but rather, comprises another shape due to
deformation. Such "deformation", may actually be the result of
radial displacement of individual strands or fibers of reinforcing
strand 1102 that occur when layers of conductor strands 1104 are
wound or twisted about generally central reinforcing strand 1102.
Such variation, may be caused by radial movement or deformation of
reinforcing strand 1102 and may vary axially, or along a length of
wire 1100. Consequently, while FIG. 37A depicts an ideal embodiment
of wire 1100 in cross section, in other embodiments wire 1100 may
comprise the relative structure depicted in FIG. 37B, or some other
similar structure. As such, embodiments of reinforced decorative
wire 1100 may include a central reinforcing strand that may only be
substantially, or mostly centrally located. Further, in such an
embodiment, conductor strands 1104 may not be evenly spaced about
reinforcing strand 1102, as depicted, nor will strands 1104 of
layer 1110 be evenly spaced about layer 1108.
[0288] As described above, embodiments of wire 1100 are not limited
to the 1-5-11 configuration described above (1 reinforcing strand
1102, 5 first layer conductors 1105 and 11 second layer conductors
1110).
[0289] Although embodiments of reinforced wire 1100 may comprise
multi-layer conductor strand embodiments, such as those depicted in
FIGS. 36-37B, embodiments of reinforced wire 1100 may include only
a single layer of conductor strands 1104 and a single reinforcing
strand 1102. Some such embodiments will be further described below,
and may include the following embodiments: 10 conductor strands
1104 with a single reinforcing strand 1102, which in an embodiment
includes 0.15-0.16 mm diameter strands 1104 and 1000 Denier strand
1102; 9 conductor strands 1104 with a single reinforcing strand
1102, which in an embodiment includes 0.15-0.16 mm diameter strands
1104 and 1000 Denier strand 1102; 8 conductor strands 1104 with a
single reinforcing strand 1102, which in an embodiment includes
0.15-0.16 mm diameter strands 1104 and 1500 Denier strand 1102; and
7 conductor strands 1104 with a single reinforcing strand 1102,
which in an embodiment includes 0.15-0.16 mm diameter strands 1104
and 1500 Denier strand 1102. In some such 7, 8, 9, or 110 stranded
embodiments, when fewer conductor strands 1104 are used, a larger
diameter and stronger reinforcing strand 1102 may be included to
make up for the decrease in tensile strength due to fewer conductor
strands 1104.
[0290] Referring to FIG. 38, another embodiment of reinforced
decorative-lighting wire 1100 is depicted. This alternate
embodiment of wire 1100 is substantially the same as the embodiment
depicted in FIGS. 36, 37A and 37B, and described above, with the
exception of reinforcing strands 1102. In this embodiment, rather
than a single reinforcing strand 1102, wire 1100 includes three
reinforcing strands 1102a, 1102b, and 1102c. Reinforcing strands
1102a-102c extend axially through the center portion of wire 1102.
Strands 1102a-102c may or may not be twisted about one another.
Twisting multiple strands 1102 may provide an additional
reinforcing strength.
[0291] In an embodiment, fewer than three strands 1102, namely two
strands may be used. In other embodiments, greater than three
strands 1102 may be used.
[0292] In an embodiment, the cross-sectional area of the three
reinforcing strands 1102a, 1102b, and 1102c is equivalent to the
1500 Denier strand described above with respect to the embodiment
of FIGS. 36, 37A and 37B. In other embodiments, the size of
reinforcing strands 1102 may be larger or smaller, depending on
desired wire 1100 strength, with larger size strands and/or more
strands 1102 being used for stronger reinforced wire 1100.
[0293] Referring to FIG. 39, another embodiment of wire 1100 is
depicted. In this embodiment, wire 1100 still includes multiple
reinforcing strands 1102, first conductor layer 1108 comprising
multiple conductors 1104, second conductor layer 1110 comprising
multiple conductors 1104, and outer insulating layer 1106. In the
depicted embodiment, first conductor layer 1108 includes five
conductors 1104 and second conductor layer 1110 includes eleven
conductors 1104, similar to the embodiments described above with
respect to FIGS. 36-38. However, in this embodiment, wire 1100
includes four reinforcing strands 1102.
[0294] As depicted, first conductor layer 1108 actually includes a
single, central conductor 1104a surrounded by four outer conductors
1104b, 1104c, 1104d, and 1104e. Between each outer conductor 1104b,
1104c, 1104d and 1104f is a reinforcing strand 1102. Second
conductor layer 1110 is adjacent both the four conductors 1104b-e,
and the four reinforcing strands 1102.
[0295] Embodiments of the invention are not intended to be limited
to the specific patterns and structures depicted in FIGS. 36-39. It
will be understood that the number of conductors 1104, number of
reinforcing strands 1102, and their combinations, may vary.
[0296] The embodiments above are intended to be illustrative and
not limiting. Additional embodiments are within the claims. In
addition, although aspects of the present invention have been
described with reference to particular embodiments, those skilled
in the art will recognize that changes can be made in form and
detail without departing from the spirit and scope of the
invention, as defined by the claims.
[0297] Persons of ordinary skill in the relevant arts will
recognize that the invention may comprise fewer features than
illustrated in any individual embodiment described above. The
embodiments described herein are not meant to be an exhaustive
presentation of the ways in which the various features of the
invention may be combined. Accordingly, the embodiments are not
mutually exclusive combinations of features; rather, the invention
may comprise a combination of different individual features
selected from different individual embodiments, as understood by
persons of ordinary skill in the art.
[0298] Any incorporation by reference of documents above is limited
such that no subject matter is incorporated that is contrary to the
explicit disclosure herein. Any incorporation by reference of
documents above is further limited such that no claims included in
the documents are incorporated by reference herein. Any
incorporation by reference of documents above is yet further
limited such that any definitions provided in the documents are not
incorporated by reference herein unless expressly included
herein.
[0299] For purposes of interpreting the claims for the present
invention, it is expressly intended that the provisions of Section
112, sixth paragraph of 35 U.S.C. are not to be invoked unless the
specific terms "means for" or "step for" are recited in a
claim.
* * * * *